S800 I/O Product Guide

Transcription

1 S800 I/O Product Guide System Version 5.1 Power and productivity for a better world TM

2

3 S800 I/O Product Guide System Version 5.1

4 NOTICE This document contains information about one or more ABB products and may include a description of or a reference to one or more standards that may be generally relevant to the ABB products. The presence of any such description of a standard or reference to a standard is not a representation that all of the ABB products referenced in this document support all of the features of the described or referenced standard. In order to determine the specific features supported by a particular ABB product, the reader should consult the product specifications for the particular ABB product. TRADEMARKS ABB may have one or more patents or pending patent applications protecting the intellectual property in the ABB products described in this document. The information in this document is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document. In no event shall ABB be liable for direct, indirect, special, incidental or consequential damages of any nature or kind arising from the use of this document, nor shall ABB be liable for incidental or consequential damages arising from use of any software or hardware described in this document. This document and parts thereof must not be reproduced or copied without written permission from ABB, and the contents thereof must not be imparted to a third party nor used for any unauthorized purpose. The software or hardware described in this document is furnished under a license and may be used, copied, or disclosed only in accordance with the terms of such license. This product meets the requirements specified in EMC Directive 2004/108/EEC and in Low Voltage Directive 2006/95/EEC. All rights to copyrights, registered trademarks, and trademarks reside with their respective owners. Copyright by ABB. All rights reserved. Release: April 2013 Document number: 3BSE A

5 Table of Contents About This Product Guide General...9 Product Guide Conventions...10 Warning, Caution, Information, and Tip Icons...10 Terminology...11 Released User Manuals and Release Notes...13 New in this Release...13 Section 1 - Key Benefits Product Benefits...18 Features...19 Section 2 - Product Description Introduction...21 Product Overview...24 S800 I/O Station...26 Base Cluster...26 I/O Cluster...26 I/O Modules...26 Functional Description...28 Product Configuration Examples...28 Communication...30 Fieldbus Communication Interface...35 Module Termination...37 ModuleBus Items...40 I/O Modules BSE A 5

6 Table of Contents Drives Integration...54 Support for connections to instruments in Hazardous Areas...57 Support for Externally Connected Accessories...58 Support for HART Communication...60 Support for Safety System Requirements...61 Redundancy Functionality...61 Software Components...62 Hardware Components...63 I/O Modules...63 Module Termination Unit...65 Fieldbus Communication Interface...72 ModuleBus...79 Power Supplies...93 Mounting Equipment G3 compliant modules I/O Station Configurations Mounting Section 3 - Technical Data and Performance Directives EMC Directive Low Voltage Directive ATEX directive Standards and Approvals Electrical Safety Hazardous Classified Locations CE-marking G3 Compliant Transport and Storage Conditions Climatic Operating Conditions Mechanical Operating Conditions EMC Overvoltage Categories BSE A

7 Table of Contents Equipment Class and Insulation Voltages Equipment Class Insulation Voltage Insulation Test Voltage Capacity and Performance Advant Fieldbus 100 Load PROFIBUS CI PROFIBUS CI S800 I/O Station Data Scanning Calculation of Maximum Distance of an Optical ModuleBus Configuration Power Supply and Cooling Requirements Supported I/O Modules and Drives via Advant Fieldbus Supported I/O Modules and Drives via PROFIBUS and CI Supported I/O Modules and Drives via PROFIBUS and CI Intrinsic Safety Parameters Certifications Section 4 - Ordering General Product and Price List Structure INDEX 3BSE A 7

8 Table of Contents 8 3BSE A

9 About This Product Guide General Any security measures described in this Product Guide, for example, for user access, password security, network security, firewalls, virus protection, etc., represent possible steps that a user of an 800xA System may want to consider based on a risk assessment for a particular application and installation. This risk assessment, as well as the proper implementation, configuration, installation, operation, administration, and maintenance of all relevant security related equipment, software, and procedures, are the responsibility of the user of the 800xA System. This Product Guide is primarily intended for sales representatives within ABB. The Product Guide is distributed to internal ABB customers and to important external customers, as a complement to existing product information. This Product Guide does not contain last-minute product information and updates which might affect functionality and/or performance. For information on late changes and restrictions, refer the Release Notes. This Product Guide describes the S800 I/O system, presenting information in terms of what can be installed and configured as well as operational possibilities. This Product Guide does not describe the different controller connect products. For more details, see separate product guides. The product guide is intended as an introduction to S800 I/O system, as well as a reference when discussing technical solutions with customers. The guide provides: Information on S800 I/O system key benefits, both on product and functional levels. An overview of functions offered by S800 I/O system. 3BSE A 9

10 Product Guide Conventions About This Product Guide Technical and Performance data for S800 I/O system. Instructions on how to order, with reference to system configurations. Product Guide Conventions Microsoft Windows conventions are normally used for the standard presentation of material when entering text, key sequences, prompts, messages, menu items, screen elements, etc. Warning, Caution, Information, and Tip Icons This Product Guide includes Warning, Caution, and Information where appropriate to point out safety related or other important information. It also includes Tip to point out useful hints to the reader. The corresponding symbols should be interpreted as follows: Electrical warning icon indicates the presence of a hazard that could result in electrical shock. Warning icon indicates the presence of a hazard that could result in personal injury. Caution icon indicates important information or warning related to the concept discussed in the text. It might indicate the presence of a hazard that could result in corruption of software or damage to equipment/property. Information icon alerts the reader to pertinent facts and conditions. Tip icon indicates advice on, for example, how to design your project or how to use a certain function Although Warning hazards are related to personal injury, and Caution hazards are associated with equipment or property damage, it should be understood that operation of damaged equipment could, under certain operational conditions, result in degraded process performance leading to personal injury or death. Therefore, fully comply with all Warning and Caution notices. 10 3BSE A

11 About This Product Guide Terminology Terminology A complete and comprehensive list of terms is included in System 800xA System Guide Functional Description (3BSE038018*). The listing includes terms and definitions that apply to the 800xA System where the usage is different from commonly accepted industry standard definitions and definitions given in standard dictionaries such as Webster s Dictionary of Computer Terms. Terms that uniquely apply to this Product Guide are listed in the following table. Term AF 100 DTM FCI Base cluster G3 compliant HART I/O cluster I/O device I/O module Description Advant Fieldbus 100 is the communications bus between the I/O stations and the Advant Controllers. (FCI to CI52x) Device Type Manager is a standardized software for configuration, diagnostics, HART data communication based on the FDT standard. The Fieldbus Communication Interface (FCI) device contains the interface to the fieldbus (e.g. AF 100), ModuleBus interface and power regulators. The FCI module can manage 24 I/O devices (up to 12 directly and to the others in 1 to 7 I/O clusters). Consists of single or red. FCIs plus I/O modules connected directly to the FCI. The module withstand more severe environmental conditions according to ISA-S Highway Addressable Remote Terminal is a digital communication protocol developed for applications in industrial process metrology. An extension of the I/O station s ModuleBus connected to the FCI by fiber optic connections. Up to 12 I/O devices per cluster. A complete I/O device consists of one MTU and one I/O module. Is an active, electronic and signal conditioning unit. Can be a part of an I/O device or a S800L I/O module. 3BSE A 11

12 Terminology About This Product Guide Term I/O station ModuleBus (ModuleBus) Extension cable MTU OSP PROFIBUS-DP PROFIBUS-DPV1 RTD SOE TC I.S. SIL HCIR CI810 CI840 TB840 Description An I/O station consists of one or two FCI(s), 1-7 I/O clusters and up to 24 I/O devices. Is an incremental, electrical or optical, bus for interconnection of I/O devices. Is used when extending the electrical ModuleBus (within the max. 2 meters). The Module Termination Unit is a passive base unit containing process terminals and a part of the ModuleBus. Outputs Set as Predetermined. A user configurable action on an output module when communications is lost to the FCI or Controller. PROFIBUS-DP is a fieldbus standard. PROFIBUS-DPV1 is a fieldbus standard. Resistance Temperature Detector. Sequence of events. Time stamping of status changes for digital inputs. Thermocouple Intrinsic Safety is a protection technique to prevent explosion in hazardous areas of a process plant. Safety Integration Level Hot Configuration in Run Stands for CI810, CI810V1, CI810V2, CI810A and CI810B Stands for CI840 and CI840A Stands for TB840 and TB840A 12 3BSE A

13 About This Product Guide Released User Manuals and Release Notes Released User Manuals and Release Notes A complete list of all User Manuals and Release Notes applicable to System 800xA is provided in System 800xA Released User Manuals and Release Notes (3BUA000263*). System 800xA Released User Manuals and Release Notes (3BUA000263*) is updated each time a document is updated or a new document is released. It is in pdf format and is provided in the following ways: Included on the documentation media provided with the system and published to ABB SolutionsBank when released as part of a major or minor release, Service Pack, Feature Pack, or System Revision. Published to ABB SolutionsBank when a User Manual or Release Note is updated in between any of the release cycles listed in the first bullet. A product bulletin is published each time System 800xA Released User Manuals and Release Notes (3BUA000263*) is updated and published to ABB SolutionsBank. New in this Release New functions in the S800 I/O system: Support for the following modules, termination units, and modems: Termination unit TU818, TU819, TU851, TU852, TU854 Digital I/O module DI818 and DI828 Digital I/O module DO818 and DO828 Always check which S800 I/O feature support is included in the controller that the I/O is connected to. 3BSE A 13

14 New in this Release About This Product Guide 14 3BSE A

15 Safety Summary Electrostatic Sensitive Device Devices labeled with this symbol require special handling precautions as described in the installation section. GENERAL WARNINGS Equipment Environment All components, whether in transportation, operation or storage, must be in a non-corrosive environment. Electrical Shock Hazard During Maintenance Disconnect power or take precautions to insure that contact with energized parts is avoided when servicing. SPECIFIC WARNINGS Page 112: In I.S. applications, modules with I.S. Interfaces MUST be mounted right most of the I/O station or as a separate group. The installation must be performed by qualified personnel. It must comply with the relevant national/international standards (e.g. IEC 79-14, CEI 64-2, BS 5345 Pt. 4, DIN VDE 165) and in-line with the established installation rules and recommended practice (e.g. CEI 64-8, ANSI/ISA RP-12.6). The conformity of hazardous area field devices with the related system documentation must always be checked. When using modules with I.S. Interfaces in non I.S.applications, the I.S. modules can be placed in any position following the same rules as non I.S. modules. SPECIFIC CAUTIONS Page 126: The calculated load of Advant Fieldbus 100 must be equal to or less than 70%. Page 128: The calculated load of Advant Fieldbus 100 must be equal to or less than 50%. NOTE! 1 ms cycle time is not allowed. Page 129: The calculated load of Advant Fieldbus 100 must be equal to or less than 50%. NOTE! 1 ms cycle time is not allowed. 3BSE A 15

16 Safety Summary 16 3BSE A

17 Section 1 Key Benefits The S800 I/O is a distributed, highly modularized and flexible I/O-system with eco-efficient design, providing easy installation of the I/O modules, process cabling and connection to drives systems. The S800 I/O modules and termination units can be mounted and combined in many different configurations to fit your space requirements and suit many types of applications. Figure 1. S800 I/O Fieldbus Communication Interface with I/O-modules on Compact and Extended MTUs 3BSE A 17

18 Product Benefits Section 1 Key Benefits Product Benefits Some of the benefits of the S800 I/O system are: Flexibility, permitting a virtually infinite number of installation arrangements for any application: small to large easy mounting on a DIN-rail Modularity, permitting step-by-step expansion Cost-effectiveness, with respect to hardware, cabling, installation and maintenance Reliability and auto-diagnostics Saves panel costs Reduces downtime Easy to configure Redundancy can be introduced on all levels 18 3BSE A

19 Section 1 Key Benefits Features Features The major features of the S800 I/O system are: Communicates over PROFIBUS-DP/DPV1 or Advant Fieldbus 100. Quick fault-finding with the help of LEDs of each module and channel. An extensive scope of Digital input/output modules and Analog input/output modules. Digital input/output modules and Analog input/output modules with Intrinsic Safety interfaces. Mounted on standard DIN-rails type NS 35/75 according to EN Support of dual redundancy in power supply, fieldbus connection and I/O channel. Support of fieldbus media supervision, bumpless change-over and failure reporting. All outputs can be individually set to freeze or to take on predefined values. Easy connection to drives systems, minimizing communication delays and cost. All modules have plastic injection molded enclosures which provide safety protection degree IP20 according to IEC 529. The plastic used is halogen free. I/O modules are protected by a mechanical keying arrangement from destruction such as if an attempt is made to insert a module type in a position with a different key code rather than the factory set code of the I/O module. Terminal units have keys which are set to key code of its I/O module s key code. (S800L I/O modules do not use Termination Units). An electrical ID is checked at start-up, if this does not match the configured type, the I/O module is not taken into operation. Hot swap of S800 I/O modules (except S800L modules) allowing replacement of faulty modules without disconnecting field power or system power to the I/O station. 3BSE A 19

20 Features Section 1 Key Benefits HART pass-through communication. I/O modules allow for 55 o C ambient temperature except for vertical mounted Compact MTU with I/O modules and vertically mounted S800L allow for 40 o C ambient temperature. Support of connection to external Intrinsic Safety Barriers. High integrity I/O modules, IEC SIL3 certified. Hot Configuration In Run via Profibus. Coated modules. Galvanic isolation between process and system. Channel based galvanic isolation is also available. SOE support by time stamped events with resolution down to 0.4 ms. Available for 24/48/125 V d.c. digital inputs. Long distance distribution in star configuration. G3 compliant. 20 3BSE A

21 Section 2 Product Description Introduction Figure 2 shows the basic construction of I/O stations without any redundancy. To increase the up-time, a number of component can be set up with redundancy: Power Supply I/O Module Fieldbus Communication Interface (FCI) Fieldbus ModuleBus 3BSE A 21

22 Introduction Section 2 Product Description Controller Electrical ModuleBus FCI I/O Module Base Cluster Fieldbus ModuleBus Optical Port Optical ModuleBus Modem I/O Cluster I/O Station Optical ModuleBus I/O Cluster Base Cluster Figure 2. I/O Station Overview 22 3BSE A

23 Section 2 Product Description Introduction An example of a system using redundancy for all these components is shown in Figure 3. Redundant Controller ModuleBus Optical Port Redundant FCI Redundant I/O module Redundant electrical ModuleBus Optical ModuleBus Modem I/O Cluster, single I/O Redundant Fieldbus Optical ModuleBus I/O Cluster, single I/O Figure 3. I/O Station Overview with Maximum Redundancy and Additional Single I/O Modules 3BSE A 23

24 Product Overview Section 2 Product Description It is not necessary to implement redundancy on all components, but there are some dependencies: Redundant FCI requires: redundant fieldbus Redundant I/O Module (only in base cluster) requires: double electrical ModuleBus redundant FCI redundant fieldbus Product Overview S800 I/O provides distributed I/O on PROFIBUS and Advant Fieldbus 100 (AF100). S800 I/O is also used as a communication link to some of ABB s Drives. With the network definition PROFIBUS, it means both the versions; PROFIBUS-DP and PROFIBUS-DPV1. An I/O station can be configured over the Fieldbus. Typical parameters are signal range, filter time, etc. The status of the modules are indicated by LEDs and also accessible over the fieldbus. Analog values are scaled 0-100% of the signal range. AI/AO modules are scanned every 4th I/O scan cycle. RTD/TC every 10th cycle. Values are transferred cyclically on the fieldbus limited by the fieldbus and the fieldbus master. The Fieldbus Communication Interface is scanning the I/O modules cyclically. The cycle time, ms, is dependent on type and number of modules. 24 3BSE A

25 Section 2 Product Description Product Overview Figure 4. S800 I/O Station In general, all S800 I/O units are G3 compliant. G3 compliant units withstand more severe environmental conditions according to ISA-S The following S800 I/O units are G2 compliant - SD831, SD832, SD833, SD834, SS832, and TB811. G3 compliant versions of SD822 and SS822 are available, refer to SD822Z and SS822Z. The modules are marked with a bar code that shows serial number, article ID and product revision number. A separate bar code strip is enclosed for optional placing on the module. The bar code is of type Bar-code BSE A 25

26 S800 I/O Station Section 2 Product Description S800 I/O Station An S800 I/O station includes: 1 (or 2 if redundant) Fieldbus Communication Interface (FCI) up to 24 S800 I/O modules divided into 1 base cluster up to 7 additional I/O clusters, each one containing up to 12 I/O modules. Base Cluster A base cluster includes: 1 (or 2 if redundancy) Fieldbus Communication Interfaces (FCI) up to 12 S800 I/O modules or 6 pairs of redundant I/O. I/O Cluster An I/O cluster includes: 1 Optical ModuleBus Modem up to 12 S800 I/O modules. I/O Modules Any combination of I/O modules is possible, within the limits in Table 1. Table 1. The max. I/O Configuration of S800 I/O Connected to Advant Fieldbus 100 and PROFIBUS. Item Max. No. S800 I/O stations per Advant Fieldbus (1) S800 I/O station per PROFIBUS BSE A

27 Section 2 Product Description I/O Modules Table 1. The max. I/O Configuration of S800 I/O Connected to Advant Fieldbus 100 and PROFIBUS. (Continued) Item S800 I/O modules per station connected via AF (2) S800 I/O modules per station connected via PROFIBUS. Supported I/O modules types. Max. No. See Chapter 3, Technical Data and Performance (1) If other than S800 I/O stations are used on the same Advant Fieldbus 100, the maximum number of S800 I/O stations must be reduced with a corresponding number of stations. (2) Without Optical ModuleBus Expansion the maximum number is 12. 3BSE A 27

28 Functional Description Section 2 Product Description Functional Description Product Configuration Examples This section includes some basic configuration examples, to give you some ideas about the use of S800 I/O. PROFIBUS An S800 I/O station can be connected to a PROFIBUS network using the Fieldbus Communication Interface (FCI) CI801/CI840. PROFIBUS master PROFIBUS Other PROFIBUS slaves S800 I/O stations with CI801/CI840 Figure 5. A PROFIBUS-DP Configuration Example 28 3BSE A

29 Section 2 Product Description Product Configuration Examples PROFIBUS with redundancy Redundancy on PROFIBUS includes redundant cable, redundant Fieldbus Communication Interface CI840 and redundant I/O modules. PROFIBUS master PROFIBUS master Other PROFIBUS slaves S800 I/O station with redundant CI840 Figure 6. A PROFIBUS-DPV1 Configuration with Redundancy Example Advant Fieldbus 100 with or without media redundancy Media redundancy on Advant Fieldbus 100 includes redundant cable, redundant modems and the CI810 FCI. AF100 master with media redundancy AF100 Other AF100 slaves S800 I/O stations with CI810 Figure 7. An AF100 Configuration with/without Media Redundancy Example 3BSE A 29

30 Communication Section 2 Product Description Advant Fieldbus 100 with redundancy Redundancy on Advant Fieldbus 100 includes redundant cable, redundant modems and redundant CI820/CI820V1 FCI together with the interconnecting unit TB815. AF100 master AF100 Other AF100 slaves S800 I/O stations with CI820/CI820V1 and TB815 CI810 Communication Figure 8. An AF100 Configuration with Redundancy Example S800 I/O uses Advant Fieldbus 100 or PROFIBUS as an external communication interface and ModuleBus as an internal communication link between clusters and their I/O modules. Advant Fieldbus 100 S800 I/O is connected to Advant Fieldbus 100 via twisted pair segment. When connected to Advant Fieldbus 100, the communication interface module and its S800 I/O modules are called as S800 I/O station. An S800 I/O station works as a slave for one parent controller. If several S800 I/O stations are connected to the same Advant Fieldbus 100 together with more than one controller, each S800 I/O station needs its own dedicated parent controller. See Figure BSE A

31 Section 2 Product Description Communication AC4XX Tool IBM PC AF100 #1 S800 I/O which works with AC4XX as Parent Controller S800I/O #1 S800I/O #2 AC110 S800I/O #3 S800 I/O which works with AC110 as Parent Controller AF100 #2 S800I/O #4 S800I/O #5 Figure 9. Connection to Advant Fieldbus 100 PROFIBUS S800 I/O and a communication interface module can be directly connected to PROFIBUS-DP or PROFIBUS-DPV1 network. When connected to PROFIBUS, the communication interface module and its S800 I/O modules are called a S800 I/O station. An S800 I/O station works as a slave on PROFIBUS. ModuleBus A Fieldbus Communication Interface module communicates with its S800 I/O modules over the ModuleBus. It communicates internally in the base cluster and externally with other additional clusters within the same S800 I/O station by using Optical ModuleBus Modems TB820, TB840 or TB840A. The Optical ModuleBus Modems are connected via optical cables to a ModuleBus Optical port module on the communication interface module. 3BSE A 31

32 Communication Section 2 Product Description The maximum length of the Optical ModuleBus expansion is dependent on the number of ModuleBus modems. The maximum length between two clusters are 15 m (50 ft.) with plastic fibre and 200 m (656 ft) with HCS glass fiber, and 1000m (3281ft) by using TB825 Optical Media Converter. The maximum fiber length between two modems is 15m (50ft) with plastic fiber, 200m (656ft) with HCS fiber and up to 5000m (20000m for S800 I/O HI) by using TB826 Optical Media Converter. Factory made optical cables (plastic fibre) are available in lengths of 1.5, 5 and 15 m (5, 16.7 or 50 ft). Within a cluster, the electrical ModuleBus is made up of increments integrated into each MTU and S800L modules. Each communication interface module and Optical ModuleBus Modem have a ModuleBus outlet connector to connect to an MTU or S800L module. An MTU and S800L module has a bus inlet and a bus outlet connector. By adding on the DIN-rail, an MTU or a S800L module to a ModuleBus master or a ModuleBus Modem, the bus is automatically expanded up to a maximum of 12 single MTUs (this number includes the number of S800L modules) or 6 redundant MTUs. It is not allowed to mix single and redundant I/O modules within a cluster. In a "Hot Replacement" configuration, you can install up to 6 I/O modules on up to 6 redundant MTUs. The electrical ModuleBus can be divided-up in sections by using Extension cables, refer Figure 34. The electrical ModuleBus must not exceed 2.5 m (100 ). The unique position codes are automatically assigned to each MTU or S800L modules as the bus is expanded. The Optional ModuleBus expansion can be built-up in three ways: simplex (ring) communication configuration. See Figure 10. duplex communication configuration. See Figure BSE A

33 Section 2 Product Description Communication star configuration with the Optical Media Converter. See Figure 12. I/O Station Maximum length of any cable is: 15 m (49 ft.) for plastic fiber 200 m (667 ft.) for HCS glass fiber Rx Tx Cluster 1 TB820 Cluster 2 TB820 Cluster 3 TB820 Cluster 7 TB820 Rx Tx Rx Tx Rx Tx Rx Tx Figure 10. Optical ModuleBus and I/O Clusters, Simplex Communication Simplex provides a one-way ring connection from the FCI to the modem, to the second modem, etc., and back from the last modem to the FCI. I/O Station Maximum length of any cable is: 15 m (49 ft.) for plastic fiber 200 m (667 ft.) for HCS glass fiber Rx Tx Cluster 1 TB820 Cluster 2 TB820 Cluster 3 TB820 Cluster 7 TB820 Rx Tx Rx Tx Rx Tx Rx Tx Rx Tx Rx Tx Rx Tx Figure 11. Optical ModuleBus and I/O Clusters, Duplex Communication Duplex provides a two-way connection, and is normally the best communication design. Duplex allows additional modems to be added down-stream on-line. A cable break or loss of a modem will only affect I/O clusters down-stream of the failure. 3BSE A 33

34 Communication Section 2 Product Description Figure 12. ModuleBus configuration with Optical Media Converter TB825/ TB BSE A

35 Section 2 Product Description Fieldbus Communication Interface Fieldbus Communication Interface A Fieldbus Communication Interface module is used as communication interface to connect S800 I/O modules to the fieldbus. There are five different FCI modules: CI801 for PROFIBUS-DPV1 CI810 for Advant Fieldbus 100, with or without media redundancy CI820/CI820V1 for Advant Fieldbus 100 fully redundant communication CI840 for PROFIBUS-DPV1 fully redundant communication They all have an isolated input for 24 V d.c. power ( V). The power source can be the SD831/ SD832/ SD833/ SD834 power supplies, battery, or other IEC664 Installation Category II power sources. Power status inputs, 2 x 24 V, to monitor 1:1 redundant mains are also provided. CI801 has a 9 pin D-sub connector and modems for PROFIBUS-DPV1 and a connection for the Optical ModuleBus via TB806/TB842. CI810 has two connectors and modems for a media redundant Advant Fieldbus 100 twisted pair cables and a connection for the Optical ModuleBus. CI820/CI820V1, together with the interconnection unit TB815, is used when a fully redundant configuration is required. CI820/CI820V1 comprises the Advant Fieldbus 100 twisted pair connection and TB815 the Optical ModuleBus connection. CI840, together with termination unit TU846/TU847, is used when a fully redundant configuration is required. CI840 is mounted on TU846/TU847 and has a connector for power supply and two 9 pin D-sub connectors for PROFIBUS-DPV1 connection. TU846/TU847 has two service ports and two address switches. CI840 also has a connection for the Optical ModuleBus via TB806/TB842 or TB846/TB842. CI801 and CI840 supports Hot Configuration in Run (HCIR) and HART passthrough. HCIR makes it possible to change the I/O station configuration without stopping the I/O station execution. The front plate of the communication modules provides LEDs for diagnostic and status indications. Two rotary switches are provided for setting of the I/O station address. No other addresses are required to be set within the I/O station. Labels for 3BSE A 35

36 Fieldbus Communication Interface Section 2 Product Description optional user text and item number are also provided. The communication plugs can be inserted/removed without interrupting the communication between stations on the bus. The type designation CI810 in this document includes all types of models CI810, CI810V1, CI810V2, CI810A and CI810B if no other information is given. Table 2. Fieldbus Communication Interface Module Type CI801 CI810 CI820/ CI820V1 CI840/ CI840A TB815 TU846 TU847 Description Fieldbus Communication Interface for PROFIBUS-DPV1. Support for Hot Configuration in Run and HART pass-through (1). PROFIBUS Modem for twisted pair cable. Power supply 24 V ( V d.c.) Rated insulation voltage 50 V. Single Advant Fieldbus 100 FCI. 2 x Advant Fieldbus 100 Modems for twisted pair cable. Power supply 24 V( V), Rated insulation voltage 50 V. Advant Fieldbus 100 FCI for redundancy configuration. Advant Fieldbus 100 modem for twisted pair cable. Power supply 24 V ( V), Rated insulation voltage 50 V. Fieldbus Communication Interface for PROFIBUS-DPV1 for redundancy configuration. Support for Hot Configuration in Run and HART pass-through (1). PROFIBUS Modem for twisted pair cable. Power supply 24 V ( V d.c.) Rated insulation voltage 50 V. Interconnection unit used with CI820/CI820V1. Module Termination Unit for dual CI840, redundant I/O. Module Termination Unit for dual CI840, non-redundant I/O. Also in a G3 compliant version (TU847Z). (1) Always check the controller documentation for information about supported functionality. 36 3BSE A

37 Section 2 Product Description Module Termination Module Termination The MTUs are totally passive units and all active circuitry is allocated to the I/O module containing process connections and ModuleBus part. For more details, refer Module Termination Unit on page 65. Table 3. S800M I/O Termination Units Module Type Description TU805 TU810/ TU810V1 TU811/ TU811V1 TU812/ TU812V1 TU813 TU814/ TU814V1 TU818 Terminal Unit, 2*18 terminals, 50 V. Used to enable 2 - and 3-wire connections on DI801 and DO801. The Terminal Unit is mounted direct on DI801 or DO801. Compact MTU, 3 * * 3 terminals, 50 V. Typically used with 24/48 V d.c binary and ma analog modules for minimum DIN-rail space. Compact MTU, 2 * 8 terminals, 250 V. Typically used with 120/230 V d.c/a.c binary modules or relay outputs for minimum DIN-rail space. Compact MTU, 25 pin D-sub Connector for field connection, 50 V (1). Typically used with 24/48 V d.c binary and ma analog modules providing easy and fast installation with pre-fabricated cables. Compact MTU, Crimp Snap-in Connector for field connection, 250 V (2). Typically used with 120/230 V d.c/a.c. binary modules. The Crimp Snap-in connector type makes it possible to mix parts from different cables into the same MTU and pre-fabricate the cabling. Compact MTU, Crimp Snap-in Connector for field connection, 50 V (3). Typically used with 24/48 V d.c binary and ma analog modules. The Crimp Snap-in connector type makes it possible to mix parts from different cables into the same MTU and pre-fabricate the cabling. Compact MTU, 40 pole screw terminal connector for field connection, 50 V. TU819 Compact MTU, Two D-sub 25 pin connector for field connection, 50V. 3BSE A 37

38 Module Termination Section 2 Product Description Table 3. S800M I/O Termination Units (Continued) Module Type TU830/ TU830V1 TU831/ TU831V1 TU833 TU834 TU835/ TU835V1 TU836/ TU836V1 TU837/ TU837V1 TU838 TU839 Description Extended MTU, 3 * * 4 terminals, 50 V. Typically used with 24/48 V d.c binary and ma analog modules. Provides terminals for field power distribution. Extended MTU, 8 * 2 terminals, 250 V. Typically used with 120/230 V d.c/a.c binary modules. Provides terminals for field power distribution. Extended MTU, 3 * * 4 spring-case terminals, 50 V. Typically used with 24/48 V d.c binary and ma analog modules. Provides terminals for field power distribution. Extended MTU, 2x16 terminals, 50 V, 8 channels with individual shunt sticks Extended MTU, 4*2 groups + 2*4 power terminals, 50 V, individually fused per channel. Channel wise fused transducer power outlets. Usable for 2-wire transmitters. Extended MTU, 2*4 groups + 2*6 power terminals, 250 V, individually fused per channel. For loads where the power supply always is taken from the MTU. Extended MTU, 2*4 groups + 2*6 power return terminals, 250 V, fused. For loads where the power supply always is taken from the MTU or without the power supply per channel. Extended MTU, 2*4 groups + 2*4 power return terminals, 50 V, fused. AI: Each channel includes terminals for current and voltage, fused power outlet and signal return. Usable for 2-, 3- and 4-wire transmitters. DI: Each channel includes terminals for 16 signals, 16 signal returns and 16 power outlets. The power outlets are wired in pairs. Each pair has a common fuse. Extended MTU, 3x2 groups + 2x3 power return terminals, 250 V, fused. 38 3BSE A

39 Section 2 Product Description Module Termination Table 3. S800M I/O Termination Units (Continued) Module Type Description TU842 TU843 TU844 TU845 TU850 Redundant horizontal MTU, 3 * * 4 terminals, 50 V for redundant I/O modules Redundant vertical MTU, 3 * * 4 terminals, 50 V for redundant I/O modules Redundant horizontal MTU, 2 * * 4 terminals, 50 V for redundant I/O modules. 8 positions for shuntsticks for current or voltage signals. Redundant vertical MTU, 2 * * 4 terminals, 50 V for redundant I/O modules. 8 positions for shuntsticks for current or voltage signals. Extended MTU, 2x8 current limited sensor power + 16 signal + 2x4 fused power connections terminals, 50 V. TU851 Extended MTU, up to 16 isolated channels, 250 V. TU852 TU854 TU890 TU891 TY801K01 TY804K01 TY820 Redundant Horizontal MTU, two 25 pin D-sub Connectors for field connection, 50V. Redundant Horizontal MTU, 25 pin D-sub Connector for field connection and individual shunt sticks, 50V. Compact MTU, I.S. applications, 50 V. For use with I/O modules with Intrinsic Safety interfaces. Compact MTU, Non I.S. applications, 50 V. For use with I/O modules with Intrinsic Safety interfaces in non-intrinsic Safety applications. Set of 8 pcs. of shunt sticks for current or voltage signals together with AI845 or AI880/AI880A and TU844 or TU845. Set of 8 pcs. of shunt sticks for NAMUR signals together with DP840 and TU844 or TU845. Temperature sensor with 4-wire connection, and used together with AI835 and AI843. 3BSE A 39

40 ModuleBus Items Section 2 Product Description Table 3. S800M I/O Termination Units (Continued) Module Type Mounting Kit Horizontal Mounting Profile Description Used for horizontal mounting of CI801, CI840 and TB840 on a vertical DIN-rail. Mounting profile with one DIN-rail and one cable duct. (1) Connector is not enclosed. (2) The three cable plugs are enclosed, see Table 4. (3) Connector is not enclosed. Three connectors are needed, see Table 4. Table 4. Cable Connectors for TU813 and TU814, Supplied by Phoenix Contact Part No Name Cable plug TU MSTBC 2.5/8-STZF-5.08 Cable plug TU MSTBC 2.5/10-ST-5.08 Crimp snap in connector MSTBC-MT MSTBC-MT MSTBC-MT Crimping tool CRIMPFOX MT 2.5 Remove insulation tool QUICK WIREFOX 6 ModuleBus Items The ModuleBus supports up to 8 cluster, one base cluster and up to 7 I/O cluster, connected to each other via optical cables, Optical ModuleBus Modems and a ModuleBus Optical port module. The cluster is built up by MTUs and/or S800L modules. At the last, MTU or S800L modules bus outlet a terminator module, TB807, must be inserted. 40 3BSE A

41 Section 2 Product Description ModuleBus Items Table 5. ModuleBus Items Module Type TB810 TB811 TB815 TB820/ TB820V2 TB825 TB826 TB840/ TB840A TB842 TB845 TB846 Description ModuleBus Optical port with 10 Mbit driver for ModuleBus Optical expansion used together with S800I/O and Drive equipment Option to the communication interface. Used together with CI810 and CI820. ModuleBus Optical port with 5 Mbit driver for ModuleBus Optical expansion used together with Drive equipment Option to the communication interface. Used together with CI810 and CI820. ModuleBus Interconnection Unit to redundant FCIs (CI820/CI820V1) Optical ModuleBus Modem. Optical and electrical ModuleBus interface. Power supply 24 V ( V), Rated insulation voltage 50 V. ModuleBus Optical Media Converter, converts between plastic opto fiber or HCS fiber with Versatile link connectors and glass optical fiber with ST connectors. Modulebus Optical Media Converter, converts plastic opto fiber or HCS fiber with Versatile link connectors to single mode glass opto fiber with SC connectors. Optical ModuleBus Modem for redundant configuration. Optical and electrical ModuleBus interface. Power supply 24 V ( V), Rated insulation voltage 50 V. ModuleBus Optical port with 10 Mbit driver for ModuleBus Optical expansion used together with S800I/O and Drive equipment Option to the communication interface. Used together with CI840. Bus Outlet. ModuleBus extent. cable adaptor D-sub 25, female. For dual ModuleBus. Bus Inlet. ModuleBus extent. cable adaptor D-sub 25, male. For dual ModuleBus or carrier for TB842. 3BSE A 41

42 ModuleBus Items Section 2 Product Description Table 5. ModuleBus Items (Continued) Module Type TK811V015 TK811V050 TK811V150 TK812V015 TK812V050 TK812V150 TB805 TB806 TB807 TK801V003 TK801V006 TK801V012 TU807 TU840 TU841 Description Optical ModuleBus expansion cable with connectors, duplex cable plastic fibre1.5 m (4.9 ft.) Optical ModuleBus expansion cable with connectors, duplex cable plastic fibre 5 m (16.4 ft.) Optical ModuleBus expansion cable with connectors, duplex cable plastic fibre 15 m (49.2 ft.) Optical ModuleBus expansion cable with connectors, Optical simplex cable plastic fibre, 1.5 m (4.9 ft.) Optical ModuleBus expansion cable with connectors, Optical simplex cable plastic fibre, 5 m (16.4 ft.) Optical ModuleBus expansion cable with connectors, Optical simplex cable plastic fibre, 15 m (492 ft.) Bus Outlet. ModuleBus extent, cable adaptor D-sub 25, female. For single ModuleBus. Bus Inlet. ModuleBus extent. cable adaptor D-sub 25, male. For single ModuleBus or carrier for TB842. ModuleBus terminator. One each per base and I/O cluster. ModuleBus extension cable. Shielded Cable 0.3m (1.0 ft.), D-sub 25, male, female. ModuleBus extension cable Shielded cable 0.6m (2.0 ft.) D-sub 25, male, female. ModuleBus extension cable Shielded cable 1.2m (4.0 ft.) D-sub 25, male, female. Module Termination Unit for single TB840/TB840A. Module Termination Unit for redundant TB840/TB840A, redundant I/O. Module Termination Unit for redundant TB840/TB840A, non-redundant I/O. 42 3BSE A

43 Section 2 Product Description I/O Modules Table 5. ModuleBus Items (Continued) Module Type TU848 TU849 TU850 Description Module Termination Unit for redundant TB840/TB840A, redundant I/O and individual power supply connections. Module Termination Unit for redundant TB840/TB840A, non-redundant I/O and individual power supply connections. Extended Module Termination Unit, 16 I/O channels, 16 current limited sensor/transmitter power outlets D-sub connectors 25 pin (male). I/O Modules For more information on Optical ModuleBus expansion cables with other length and performance, see Opto Connectors and Cables on page 87. S800 I/O system provides a variety of I/O modules, covering analog and digital signals of various types, and interfaces for RTDs and TCs of various types. For positioning applications by using incremental encoders, a special interface unit is available comprising a complete positioning loop. The S800 I/O system provides I/O modules with typically 2-32 channels depending on type and ratings of the individual module. All I/O modules are supervised at system start-up as well as under normal operation. The status of an S800 I/O module is indicated with front mounted LEDs; RUN (R), green, normal operation, FAULT (F), red, when a fault is detected, WARNING (W), yellow, when a channel fault is detected and OUTPUT SET AS PREDETERMINED (O), yellow, when the module has lost communication (for output modules). S800L I/O modules only have one STATUS (S) LED showing RUN (green) and FAULT (red). All S800 I/O modules (except S800L) can be replaced with both system power and field power connected. Digital I/O Modules All the digital I/O modules have galvanic isolation relative to chassis ground. All modules have LEDs to indicate channel status (on/off) and the standard set of 3BSE A 43

44 I/O Modules Section 2 Product Description module status indicators. Some output modules and modules with Intrinsic Safety interfaces have indication for the channel error status. The S800 I/O modules 24/48 V d.c. have channels isolated in groups. Each group has a field power status input to indicate presence of field power. The loss of field power is indicated on Warning LED, module status set to warning and channel status set to error. The 120/250 V a.c. or d.c. modules have individually isolated channels. The input module can be configured to monitor field power status. S800L I/O modules 24 V d.c. have one isolated group with 16 channels, used together with TU805 enable 2-and 3-wires connections. The input modules can be configured to monitor field power status. Loss of field power will set module status to warning and channel status to error. Outputs do not need external inductive load suppression components. Table 6. S800 Digital Modules Module Type Type (1) Description DI801 L Digital Input 24 V d.c., 1*16 channels (2) Rated insulation voltage 50 V Suitable MTU (3) DI802 L Digital input 120 V a.c., 110 V d.c. 8*1 channels Rated insulation voltage 250 V DI803 L Digital input 230 V a.c., 220 V d.c. 8*1 channels Rated insulation voltage 250 V DI810 Digital Input 24 V d.c., 2*8 channels (4) Rated insulation voltage 50 V TU810 TU812 TU814 TU818 TU830 TU833 TU836 TU837 TU BSE A

45 Section 2 Product Description I/O Modules Table 6. S800 Digital Modules (Continued) Module Type Type (1) Description DI811 Digital Input 48 V d.c., 2*8 channels (3) Rated insulation voltage 50 V DI814 Digital Input 24 V d.c. 2*8 channels (4), current source. Rated insulation voltage 50 V DI818 Digital Input 24 V, 2*16 channels (5) Current Sinking Rated isolation voltage 50 V Suitable MTU TU810 TU812 TU814 TU818 TU830 TU833 TU836 TU837 TU850 TU810 TU812 TU814 TU830 TU833 TU836 TU837 TU850 TU830 TU818 TU819 DI820 DI821 Digital Input 120 V a.c., 110 V d.c., 8*1 channels Rated insulation voltage 250 V. Digital Input 230 V a.c., 220 V d.c., 8*1 channels Rated insulation voltage 250 V. TU814 TU831 TU839 TU814 TU831 TU839 DI828 Digital Input 120 a.c/d.c, 16*1 Rated isolation voltage 250 V. TU851 DI825 Digital Input 8*1 galvanic isolated channels, 125 V d.c. with sequence of event (SOE) handling. TU814 TU831 TU839 3BSE A 45

46 I/O Modules Section 2 Product Description Table 6. S800 Digital Modules (Continued) Module Type Type (1) Description Suitable MTU DI830 Digital Input 24 V d.c. 2*8 channels SOE handling. Rated insulation voltage 50 V TU810 TU812 TU814 TU830 TU833 TU838 TU850 DI831 Digital Input 48 V d.c. 2*8 channels SOE handling. Rated insulation voltage 50 V TU810 TU812 TU814 TU830 TU833 TU838 TU850 DI840 Digital Input 24 V 1*16 channels SOE handling. Rated insulation voltage 50 V. Advanced on-board diagnostics. For single and redundant applications. Redundant: TU842 TU843 TU818 TU838 Single: as DI830 DI880 (6)(7)(8) High Integrity Digital Input 24 V d.c. 1*16 channels For single and redundant applications. TU810 TU812 TU814 TU818 TU830 TU833 TU842 TU843 TU BSE A

47 Section 2 Product Description I/O Modules Table 6. S800 Digital Modules (Continued) Module Type Type (1) Description Suitable MTU DI885 DI890 Digital Input 24/48 V d.c.1*8 channels open-circuit monitoring, SOE handling. Rated insulation voltage 50 V Digital Input, I.S. interface, 8*1 channels Galvanic insulation between channels. Rated insulation voltage 50 V. DO801 L Digital Output 24 V d.c. 0.5 A protected, 1*16 channels (2) Rated insulation voltage 50 V DO802 L Digital Output Relay 8*1 channels, V a.c./110 V d.c. 2 A cos d.c. < 60 W. Varistor protected Rated insulation voltage 250 V. DO810 DO814 DO815 (9) Digital Output 24 V d.c. 0.5 A protected, 2*8 channels (4) Rated insulation voltage 50 V. Digital Output 24 V d.c. 0.5 A protected, 2*8 channels (4), current sink Rated insulation voltage 50 V Digital Output 24 V d.c. 2 A protected, 2*4 channels. Rated insulation voltage 50 V. TU810 TU812 TU814 TU818 TU830 TU833 TU890 TU891 (3) TU810 TU812 TU814 TU830 TU833 TU810 TU812 TU814 TU830 TU833 TU810 TU812 TU814 TU830 TU833 3BSE A 47

48 I/O Modules Section 2 Product Description Table 6. S800 Digital Modules (Continued) Module Type Type (1) Description Suitable MTU DO818 Digital Output 24 V d.c. 0.5 A protected, 2*16 channels (5) Rated insulation voltage 50 V. TU830 TU818 TU819 DO820 Digital Output Relay 8*1 channels V a.c. 3 A cos 0.4 d.c. < 42W. Varistor protected Rated insulation voltage 250 V. TU811 TU813 TU831 TU836 TU837 DO821 Digital Output Relay 8*1 normally closed channels V a.c./d.c. 3 A cos 0.5 d.c. < 42 W Varistor protected Rated insulation voltage 250 V TU811 TU813 TU831 TU836 TU837 TU851 DO828 Digital Output Relay 16*1 channels 125Vd.c./250V a.c. Rated isolation voltage 250 V. TU851 DO840 Digital Output 24 V d.c. 0.5 A protected, 2*8 channels Rated insulation voltage 50 V. Advanced on-board diagnostics. For single and redundant applications. Redundant: TU842 TU843 TU852 Single: as DO810 DO880 (6) High Integrity Digital Output 24 V d.c. 1*16 channels For single and redundant applications. See DO840 DO890 Digital Output 11 V 40 ma, I.S. interface, 4*1 channels Galvanic isolation between channels Rated insulation voltage 50 V TU890 TU BSE A

49 Section 2 Product Description I/O Modules Table 6. S800 Digital Modules (Continued) Module Type Type (1) Description Suitable MTU DP820 Pulse Counter 2 channels Pulse count and frequency measurement 1.5 MHz 2* inputs and 1* outputs for gated counting, counter synchronization and open loop positioning Rated insulation voltage 50 V. TU810 TU812 TU814 TU830 TU833 DP840 Pulse Counter 8 channels Pulse count or frequency measurement 20 khz. Interface for NAMUR, 12 V and 24 V. The input can be read as digital input signals. For single and redundant applications. Rated insulation voltage 50 V. TU810 TU812 TU814 TU818 TU830 TU833 TU842 TU843 TU844 TU845 TU852 TU854 (1) Type L = S800L I/O (2) 1*16, equals 1 groups of 16 channels (3) With TU805 enables 2- and 3-wires connections. (4) 2*8, equals 2 groups of 8 channels (5) 2*16, equals 2 groups of 16 channels (6) Only to be used with AC 800M controller PM865 on ModuleBus. (7) If single Compact MTUs (TU810, TU812 or TU814) are used, refer to the Technical Description 3BSE (8) If the outgoing sensor supplies are not used to feed the sensor in the field, refer to the Technical Description 3BSE (9) TU812 is not recommended due to the maximum rated current. 3BSE A 49

50 I/O Modules Section 2 Product Description Analog I/O Modules All the analog I/O modules have galvanic isolation relative to chassis ground in a group of 4 or 8 channels. Some of the modules also has isolation between channels. The modules have the standard set of module status indicators. The open circuit detection is available for inputs and outputs configured for 4 20 ma and for the RTD and TC inputs. Table 7. S800 Analog Modules Module Type Type (1) Description Suitable MTU AI801 L Analog Input 1*8 channels ma, ma, 12 bit., 0.1% Current shunt resistor 250 is protected to 30 V. Rated insulation voltage 50 V. - AI810 AI815 AI820 Analog Input 1*8 channels ma, ma, 0 10 V, V, 12 bit., 0.1% Current shunt resistor 250 is protected to 30 V. Rated insulation voltage 50 V. Analog Input 1*8 channels ma, ma, 0 5 V, V, 12 bit., 0.1% Current shunt resistor 250 is protected to 11 V. Rated insulation voltage 50 V. Analog Input differential 1*4 channels ma, ma, ma, V, V, V, V, V, V, 14 bit + sign, 0.1%, CMV 50 V. Current shunt resistor 250 is protected to 30 V. Rated insulation voltage 50 V TU810 TU812 TU814 TU818 TU830 TU833 TU835 TU838 TU810 TU812 TU814 TU830 TU833 TU835 TU838 TU810 TU812 TU814 TU830 TU BSE A

51 Section 2 Product Description I/O Modules Table 7. S800 Analog Modules (Continued) Module Type Type (1) Description Suitable MTU AI825 AI830/ AI830A AI835/ AI835A AI843 Analog Input 4*1 channels for applications requiring galvanic isolated channels, ma, 0(4)...20 ma, V, 0(2)...10 V Analog Input 1*8 ch, Pt100 ( o C, o C, o C), Ni100 ( o C), Ni120 ( o C), Cu10 ( o C) Resistor ( ), 14 bit. Pt100 according to IEC751 ITPS-68, IEC ITP-90, US Ind Std, US lab Std, JIS C 1604:1981 and JIS C 1604:1997 Ni100 according to DIN Ni120 according to MIL-T-24388C Cu10 according to TCR Rated insulation voltage 50 V. Analog Input 1*8 ch Thermocouple (TC), type B ( o C), type C ( o C), type E ( o C), type J ( o C), type K ( o C), type N ( o C), type R ( o C), type S ( o C), type T ( o C), linear mv, 14 bit. Rated insulation voltage 50 V. Analog Input 1*8 ch Thermocouple (TC), -30 mv to 75 mv linear, or TC types B, C, E, J, K, L, N, R, S, T, and U, 16 bit. Rated insulation voltage 50 V Advanced on-board diagnostics. For single and redundant applications. TU811 TU813 TU831 TU810 TU812 TU814 TU830 TU833 TU810 TU812 TU814 TU818 TU830 TU833 TU818 TU830 TU833 TU842 TU843 TU852 3BSE A 51

52 I/O Modules Section 2 Product Description Table 7. S800 Analog Modules (Continued) Module Type Type (1) Description Suitable MTU AI845 Analog Input 1*8 channels ma, ma, V, V, 12 bit, 0,1%. HART interface. Rated insulation voltage 50 V. Advanced on-board diagnostics. For single and redundant applications. Redundant: TU844 TU845 TU818 TU854 Single: as AI810 AI880/ AI880A (2) AI890 AI893 AI895 High Integrity Analog Input 1*8 channels ma, ma For single and redundant applications. AI880A has support for HART pass-through communication. Complies with the NAMUR recommendation NE43. Analog Input 1*8 channels ma, ma, 12 bit, 0.1% I.S. interface. Rated insulation voltage 50 V Analog Input 1*8 channels for 2- or 3-wire RTD and Thermocouple RTD: Pt..., Ni..., Cu... and linear TC: B, C, D, E, J, K, L, N, R, S, T, U and linear 15 bit + sign, I.S. interface Rated insulation voltage 50 V. Analog Input 1*8 channels ma, 12 bit, 0.1% I.S. and HART interface. Rated insulation voltage 50 V. TU834 TU844 TU845 TU854 TU890 TU891 TU890 TU891 TU890 TU891 AO801 L Analog Output 1*8 channels, 0 20 ma, ma, 12 bit, 0.1%. RL maximum 850 Ohms. Rated insulation voltage 50 V BSE A

53 Section 2 Product Description I/O Modules Table 7. S800 Analog Modules (Continued) Module Type Type (1) Description Suitable MTU AO810/ AO810V2 Analog Output 1*8 channels, 0 20 ma, ma, 14 bit, 0.1%. RL maximum 500/850 Ohms. Rated insulation voltage 50 V. TU810 TU812 TU814 TU830 TU833 AO815 Analog Output 1*8 channels, ma, 14 bit, 0.1%. RL maximum 750 Ohms. Rated insulation voltage 50 V. TU810 TU812 TU814 TU830 TU833 AO820 AO845/ AO845A AO890 Analog Output 4*1 channels, ma, ma, ma, V, V, V, 12 bit + sign, 0.1%, individually isolated. Current output RL maximum 550 Ohms. Voltage output RL minimum 2 kohms. Rated insulation voltage 50 V. Analog Output 1*8 channels ma, 12 bit, 0,1%. HART interface, RL maximum 750 Ohms. Rated insulation voltage 50 V. Advanced on-board diagnostics. For single and redundant applications. Analog Output 1*8 channels ma, ma, 12 bit, 0.1% I.S. interface, RL maximum 750 Ohms. Rated insulation voltage 50 V TU810 TU812 TU814 TU830 TU833 Redundant: TU842 TU843 TU852 Single: as AO810/ AO810V2 TU890 TU891 AO895 Analog Output 1*8 channels ma, 12 bit, 0.1% I.S.and HART interface, RL maximum 750 Ohms. Rated insulation voltage 50 V. TU890 TU891 (1) Type L = S800L I/O (2) Only to be used with AC 800M controller PM865 on ModuleBus. 3BSE A 53

54 Drives Integration Section 2 Product Description Drives Integration The ABB Standard and Engineered drives can be connected to the S800 I/O system. The FCI works as a communication link between the fieldbus master and the drives. No application software concerning this functionality is stored in the FCI. Check the available support for each FCI type. The following drives are considered to be standard drives: ACS400 with standard drive ACS600/800 with standard application ACS600/800 with crane application ACS600/800 with pump and fan application (PFC) DCS400/500 with standard drive DCS600 with crane application The following drives are considered to be engineered drives: ACS600/800 with system application ACS600/800 with system application (PMSM) ACS600/800 IGBT with supply (ISU) application ACS600/800 with Multi Block Programming application ABxR7xxx ACS800 with crane application ACS800 Rolling Mill Application (RMO) A4xR7xxx ACS800LC DSU with diode supply unit applications ACS6000C with cyclo converter drive ACS6000SD with synchronous drive ACS6000AD with asynchronous drive ACS1000 with standard drive DCS600 with system application DCS600 with crane application 54 3BSE A

55 Section 2 Product Description Drives Integration Product Benefits By integrating drives and the control system, full advantage can be taken to added functions. The process data are measured with improved accuracy for even more exact process control, while the ready-made information permits a total overview of the drives in the process. Features The ABB drives integration includes features such as: Fieldbus solutions which results in lower wiring costs. Optical transmission between FCI and drives allows installations in an electrical disturbed environment. Faults in drives available as alarms and in diagnostic displays reduces troubleshooting and maintenance costs. Warnings from drives available as events and in diagnostic displays, allows the operator to determine, when preventive service is needed. Predefined type circuit solutions reduces project engineering and commissioning. The connection is made directly to the drives system through an optical ring or a star by using a Distributed Branching Unit. One important aspect is the simplicity in the connection. No extra hardware is needed in any of the devices, that is, the functions are included in the basic products, minimizing communication delays and cost. 3BSE A 55

56 Drives Integration Section 2 Product Description Figure 13. Examples of Drives Integration Information from the drives: The process values are sent as cyclic data, with an updating frequency decided by the application engineer. The data enables the control system to have access to basic information such as speed, current, torque and diagnostic information. Information from the fieldbus master: A setpoint for speed or torque, in percentage or absolute values can be sent. It is also possible to give commands to the drive, for example, start, stop and fault reset. 56 3BSE A

57 Section 2 Product Description Support for connections to instruments in Hazardous Areas TB810 and TB842 are equipped with a transmitter/receiver for up to 10 Mbit/s and TB811 for up to 5 Mbit/s. A ModuleBus must have the same type of transmitter/receiver on each node. Support for connections to instruments in Hazardous Areas S800 I/O provide two possibilities to connections of instruments in Hazardous areas, both integrated with special I/O modules and with support for external Intrinsic Safety systems. The S800 I/O includes I/O modules and MTU with Intrinsic Safety interfaces, namely AI890, AI893, AI895, AO890, AO895, DI890, DO890 and TU890. The interfaces are classified Ex ia, Group IIC and the modules are ATEX certified. The correct and safe operation of the Intrinsic Safety aspects of MTU and I/O Modules with Intrinsic Safety interfaces calls for expert installation and commissioning as well as correct operation and meticulous maintenance. Only those persons conversant with the installation commissioning, operation and maintenance of similar apparatus and who has the necessary qualifications should work on these products. Ensure that the installation is carried out observing the safety regulations pertaining to the installation, operation of electrical systems, and the directives and guidelines on explosion protection (Hazardous Area equipment should comply with the descriptive system document). The set of I/O modules and MTUs are not intended for hazardous area installation unless it is included in a suitable enclosure which conforms to the applicable standards. To mount the equipment in a Zone2 hazardous area then an enclosure or cabinet which provides ingress protection of IP54 rating is required. For I.S. applications, the maximum limit for AC power supply is 250 V rms and the user must ensure that the DC power supply to the FCI and I/O is limited to 60 V. 3BSE A 57

58 Support for Externally Connected Accessories Section 2 Product Description Support for Externally Connected Accessories ABB delivery S800 I/O module Connection to External Intrinsic Safety System The Intrinsic Safety System from Pepperl+Fuchs (manufacturer outside ABB) is supported via S800 I/O modules and a special MTU. The supported Intrinsic Safety System is the HiD Series The S800 I/O modules are connected via MTU TU812/TU812V1, a standard cable from Pepperl+Fuchs and a specific adapter board, one for each I/O module types according to Table 8. The standards of cables m (0.66 ft) and 1.3 m (4.3 ft). The maximum cable length is 100 m (109 yd). Terminal unit Table 8. Supported Modules and Intrinsic Safety Components Termination and adaptor board Pepperl+Fuchs delivery Intrinsic Safety modules Note AI810 TU /HAT/ABB-AI-H , 2030, 2062, 2072 Dual channel modules AO810/ AO810V2 (1) Loop-disconnected terminals 2108/HAKE/ABB-AI-H-01 (1) 2026, 2030 using passive connection Dual channel modules TU /HAT/ABB-AO-H , 2034, 2038 Dual channel modules 2108/HAKE/ABB-AO-H-01 (1) 2032, 2034, 2038 Dual channel modules DI810 TU /HAT/ABB-DI , 2844 Quad channel modules DO810 TU /HAT/ABB-DO , 2874, 2876, 2878 Dual channel modules 2108/HAKE/ABB-DO-H-01 (1) 2872, 2874, 2876, 2878 Dual channel modules 58 3BSE A

59 Section 2 Product Description Support for Externally Connected Accessories Figure 14. Example of Connection between S800 I/O and Intrinsic Safety System from Pepperl+Fuchs Pepperl+Fuchs can provide a HART protocol connection to I/O modules integrated with the Intrinsic Safety system using the MUX 2700 Remote Board for HART. Figure 15. Example of Connection between S800 I/O and Intrinsic Safety System and HART Protocol Connection Connection to ABB Entrelec Interfast Pre-wiring Solutions ABB Entrelec offers solutions for fast termination solutions with pre-wired cables and an assortment of terminations and signal adaptions. This offer connects to S800 I/O via the TU812 termination unit which provides a D-sub connector. Multipurpose cables are also available. Further information is available in the ABB Entrelec catalog "Pre-wiring system for PLC's, Interfast", 1SNC127001C0206. Connection to Phoenix Contact Varioface solutions The Phoenix Contact offers solutions for fast termination solutions with pre-wired cables and an assortment of terminations and signal adaptions. This offer connects 3BSE A 59

60 Support for HART Communication Section 2 Product Description to S800 I/O via the TU812 termination unit which provides a D-sub connector. For further information, refer the link Support for HART Communication S800 I/O provides possibilities to communicate via HART protocol with HART Field Devices via PROFIBUS-DPV1 using CI840 or CI801 or AF100 using CI810 or CI820. There are four I/O modules that have HART interface, AI815, AI845, AO815, AO845, AO845A, AI895 and AO895. For HART connection via external HART MUX, see Support for connections to instruments in Hazardous Areas on page 57. S800 I/O provides the possibilities for HART communication, but the user function is defined by the system (operator stations and controllers) S800 I/O is included in. Always read the relevant system documentation for information about the supported features and needed components of S800 I/O. On PROFIBUS, an Extended HART mode gives a possibility to pass-through long HART data frames up to 227 bytes. This will reduce the possible amount of I/O modules per station. The longest HART data frame without the Extended HART mode is 64 bytes. 60 3BSE A

61 Section 2 Product Description Support for Safety System Requirements Support for Safety System Requirements The High Integrity I/O is certified for EN SIL3. The High Integrity I/O has to be used together with a certified controller to comply with the standards. There are three modules that belong to the High Integrity I/O family that are certified for these standards, AI880/AI880A, DI880 and DO880. The modules are supported by the AC 800M controller PM865 only and have to use the Optical ModuleBus Modem TB840 when adding optical clusters. Make sure installation is carried out observing the requirement and guidelines in the documentation. FCIs and TB820 cannot handle High Integrity I/O modules. Redundancy Functionality Fieldbus Communication Interface (FCI) When using redundant FCI, one is primary and one is secondary. If the primary FCI fails it will hand over to the secondary FCI. If using redundant FCI and redundant electrical ModuleBus, the primary FCI will control both electrical ModuleBuses. When the primary FCI fails, the secondary FCI will take control of both electrical ModuleBuses. Input Modules When using redundant input modules, all reading is done from the primary input module. The input module will diagnose itself, and when the primary input module fails the secondary input module will be set as primary instead. The secondary input module is checked for error status at a lower cycle rate than the primary. Analog Output Modules When using redundant AO modules, half the output current is generated from each AO module. The AO module will diagnose itself, and when one fails, it disconnects and a direct communication between the two redundant AO modules will ensure that the second AO module quickly doubles its output current. 3BSE A 61

62 Software Components Section 2 Product Description Digital Output Module When using redundant DO modules, they both work parallel to each other. They give the same output, and the small time difference between them, in setting a signal high or low, does not make a difference. When one DO module fails it will give output signals set to low. The DO module that still work will override by setting some signals to high. Software Components Fieldbus Communication Interface The system software of a Fieldbus Communication Interface comprises a real-time operating system. The software is installed at delivery. The upgrades are available for download for the system software for field upgrade. The cables to connect a standard PC with the FCI are available in the S800 I/O price list. 62 3BSE A

63 Section 2 Product Description Hardware Components Hardware Components The highly modularized hardware of S800 I/O includes the following components: I/O Modules Module Termination Units (MTUs). Fieldbus Communication Interface ModuleBus Items The communication interface modules, Optical ModuleBus Modem, MTUs and S800 I/O modules are mounted on standard DIN-mounting rails according to EN50022 NS 35/7,5. An S800 I/O station can consist of a base cluster and up to 7 additional I/O clusters. The base cluster consists of a communication interface module and up to 12 I/O modules. I/O cluster 1 to 7 consist of an Optical ModuleBus Modem and up to 12 I/O modules. An S800 I/O station can have up to 24 I/O modules in total. I/O cluster 1 to 7 are connected to the communication interface module through an optical expansion of the ModuleBus. I/O Modules There are two types of S800 I/O modules: S800 I/O modules designed to be used together with the Module Termination Units. See Figure 20 and Figure 22. S800L I/O modules designed to be directly mounted on a standard DIN-rail and containing process connection, via detachable connectors. The S800L modules have only mechanical lock device and cannot be removed with power on. as accessories to 24 V DI/DO modules, Terminal Unit TU805 enables 2- and 3-wires connections, see Figure 17. 3BSE A 63

64 I/O Modules Section 2 Product Description Next module Centre of DIN-rail 58,5 Figure 16. Dimensions for S800L Modules 64 3BSE A

65 Section 2 Product Description Module Termination Unit 58.5 Module Termination Unit Figure 17. S800L Module with TU805 Module Termination Units (MTUs) act as I/O module carriers and are available as Compact, Extended, Intrinsic Safety and Redundant MTUs. A Compact MTU normally offers termination of one wire per channel for a 16 channel module. With Compact MTUs power distribution of field circuits must be made with external terminal blocks and current limiting components if required. Extended MTUs with group-wise isolated interfaces allow for two or three wire termination of field circuits and provide group-wise or individually fuses for powering field objects. Extended MTUs which offer two or three wire terminations allows direct field object cable termination. The need for external marshalling is therefore drastically reduced or eliminated when Extended MTUs are used. An Intrinsic Safety MTU offers termination of field objects located in hazardous areas. A redundant MTU have two ModuleBuses, two positions for I/O modules and a common process connection. 3BSE A 65

66 Module Termination Unit Section 2 Product Description Compact and Intrinsic Safety MTUs are 58mm (2.3 ) wide, Extended MTUs are 120mm (4.72 ) wide and Redundant MTUs are 124 mm (4.88 ) wide. The MTU types can be mixed and matched within an I/O station to fit a user s needs. Choice of MTU type can be made freely, trading space versus termination needs. MTUs are available with rated insulation voltages 50 V and 250 V. The 50 V types can be used with all 24/48 V discrete I/O and analog I/O modules. The MTUs with 250 V rated insulation voltage are used with all 120 V and 250 V rated I/O modules. An inserted I/O module is assigned the unique position identity of its MTU. Through the incremental bus design the physical size of an S800 I/O installation is directly proportional to the number of installed MTUs. The S800 I/O modules can be inserted and removed from MTUs without disturbing system operation. The physical lock for S800 I/O which locks an I/O module to its MTU allows I/O module removal only when the lock is in its unlocked position. The locking mechanism also acts as a logic lock so that an I/O module is operable only when the lock is in the locked position. If the lock is in its unlocked position, output channels are de-energized and I/O modules can be inserted/removed without the need to remove system or field power. 66 3BSE A

67 Section 2 Product Description Module Termination Unit Figure 18. Typical Extended MTU with I/O Module 3BSE A 67

68 Module Termination Unit Section 2 Product Description Figure 19. Typical Compact MTU with I/O Module 68 3BSE A

69 Section 2 Product Description Module Termination Unit 7 mm (.27 ) 122 mm (4.8 ) 119 mm (4.68 ) 92.5 mm (3.64 ) Center of DIN-rail 192 mm (7.6 ) E D C F B A E D C F B A 99.5 mm (3.92 ) 8 mm (0.31 ) 9 mm (0.35 ) 40 mm (1.57 ) 5 mm (0.2 ) 31.5 mm (1.24") 58 mm (2.28 ) 58.5 mm (2.30 ) Figure 20. Compact MTU for Intrinsic Safety without and with I/O Module 3BSE A 69

70 Module Termination Unit Section 2 Product Description Figure 21. Typical Horizontal Redundant MTU 70 3BSE A

71 Section 2 Product Description Module Termination Unit 122 mm (4.8 ) Figure 22. MTU with I/O Module 3BSE A 71

72 Fieldbus Communication Interface Section 2 Product Description Fieldbus Communication Interface The Fieldbus Communication Interface (FCI) module is a configurable communication interface which performs operations such as signal processing, gathering of various supervision information, OSP handling and configuration of re-inserted I/O modules. The FCI connects to a controller by way of different types of fieldbuses. Figure 23. CI801 FCI Dimensions 72 3BSE A

73 Section 2 Product Description Fieldbus Communication Interface Figure 24. CI810 FCI Dimensions 3BSE A 73

74 Fieldbus Communication Interface Section 2 Product Description Figure 25. CI820 FCI Dimensions 74 3BSE A

75 Section 2 Product Description Fieldbus Communication Interface Figure 26. TB815 Interconnection Unit Dimensions 3BSE A 75

76 Fieldbus Communication Interface Section 2 Product Description Figure 27 shows the TB815 configured with two CI820 FCIs for redundant operation. F T1 PR R P T2 DU M O D U L E B U S F T1 PR R P T2 DU SERVICE SERVICE CI820 STN. ADDR x x TB815 CI820 STN. ADDR x x SWX.X/Y L+ L+ SA L- L- SB AF SH SH Tx Rx SWX.X/Y L+ L+ SA L- L- SB AF SH SH Figure 27. Redundant CI820 FCIs and TB815 Interconnection Unit Layout Figure 28 shows the MTU TU847 (TU846) with redundant CI840. TU847 has one ModuleBus and are used for single I/O modules. TU846 has two ModuleBuses and are used for redundant I/O modules. 76 3BSE A

77 Section 2 Product Description Fieldbus Communication Interface 128 mm (5.04 ) 124 mm (4.88 ) 162 mm (6.38 ) 186 mm (7.32 ) Figure 28. Redundant CI840 FCI and MTU TU847. 3BSE A 77

78 Fieldbus Communication Interface Section 2 Product Description Figure 29. Dimension for typical MTU for CI840 or TB840 S800M I/O modules may be exchanged during system operation. A module locking mechanism disconnects ModuleBus and process signals safely from the module. A newly inserted I/O module is automatically put into operation if the system identifies the module being correct type and without faults. 78 3BSE A

79 Section 2 Product Description ModuleBus ModuleBus TB820/TB820V2 ModuleBus Modem The TB820/TB820V2 ModuleBus Modem is a fiber optic interface to the ModuleBus. The ModuleBus Modem has an electrical and an optical interface which are logically the same bus. A maximum of 12 I/O modules can be connected to the electrical ModuleBus and up to seven clusters can be connected to the fiber optic ModuleBus. The TB820/TB820V2 ModuleBus Modem has a rotary switch that selects its cluster number, 1 to 7, on the Optical ModuleBus. The ModuleBus Modem communicates with the FCI or Controller via the Optical ModuleBus. The TB820/TB820V2 ModuleBus Modem provides 24 V d.c. protected (from the source) and an isolated, protected 5 V d.c. power to the cluster s I/O modules by way of the electrical ModuleBus connection. One power source (single or redundant 24 V d.c.) can be connected to the power terminals (L+ & L-). The redundant power supply can be supervised via inputs SA and SB. 3BSE A 79

80 ModuleBus Section 2 Product Description Figure 30. TB820/TB820V2 ModuleBus Modem 80 3BSE A

81 Section 2 Product Description ModuleBus TB840/TB840A ModuleBus Modem and TU807/TU840/TU841/TU848/TU849 Module Termination Unit The TB840/TB840A ModuleBus Modem is a fiber optic interface to the Optical ModuleBus. TB840/TB840A is used in redundancy configurations where each module is connected to different Optical ModuleBus lines, but connected to the same electrical ModuleBus. Termination Unit TU840 connects TB840 to redundant I/O. Termination Unit TU841 connects TB840 to non-redundant I/O. Termination unit TU848 has individual power supply connections and connects TB840 to redundant I/O. Termination unit TU849 has individual power supply connections and connects TB840 to non-redundant I/O. TB840 can be used as single with TU807. The ModuleBus Modem has an electrical and an Optical ModuleBus interface which are logically the same bus. A maximum of 12 I/O modules can be connected to the electrical ModuleBus and up to seven clusters can be connected to the fiber optic ModuleBus. The cluster address sets by a rotary switch on the Termination Unit TU807/TU840/TU841/TU848/TU849 in range 1 to 7. The TB840/TB840A ModuleBus Modem provides 24 V d.c. protected (from the source) and an isolated, protected 5 V dc power to the cluster s I/O modules by way of the electrical ModuleBus connection. One power source (single or redundant 24 V d.c.) can be connected to the power terminals (L+ & L-). The redundant power supply can be supervised via inputs SA and SB. The rotary switch and the connectors for power supply is located on TU807/TU840/TU841/TU848/TU849. See Figure 31, for dimensions see also Figure 29. 3BSE A 81

82 ModuleBus Section 2 Product Description 128 mm (5.04 ) 47 mm (1.85 ) 124 mm (4.88 ) 162 mm (6.38 ) 186 mm (7.32 ) Only TU848/TU849 Figure 31. TB840 and TU840/TU BSE A

83 Section 2 Product Description ModuleBus TB825 Optical Media Converter ModuleBus Optical Media Converter, converts between plastic opto fiber or HCS fiber with Versatile link connectors and glass optical fiber with ST connectors. The TB825 is built in S800L mechanics and DIN-rail mounted Figure 32. TB825 Optical Media Converter 3BSE A 83

84 ModuleBus Section 2 Product Description TB826 Optical Media Converter TB826 is a Long Range Optical Media Converter for the ModuleBus. It is used to convert between plastic/opto fiber or HCS fiber with Versatile link connectors and single mode field fiber with SC connector. The TB826 is built in S800L mechanics and DIN-rail mounted. Figure 33. TB826 Optical Media Converter 84 3BSE A

85 Section 2 Product Description ModuleBus ModuleBus Optical Port, TB810/TB811 The ModuleBus Optical ports TB810/TB811 have two connectors for the Optical ModuleBus expansion and one connector for connection to the Fieldbus Communication Interface module, (FCI). The ModuleBus Optical ports are used together with the communication modules CI810, CI820/CI820V1 and (TB815). TB810/TB811 is connected directly on the FCI. 20 mm (0,79 ) 39,6 mm (1,6 ) Tx Rx 39,6 mm (1,6 ) Rx Tx Figure 34. ModuleBus Optical Port TB810/TB811 3BSE A 85

86 ModuleBus Section 2 Product Description ModuleBus Optical Port, TB842 The ModuleBus Optical port TB842 has two connectors for the Optical ModuleBus expansion and one connector for connection to the Fieldbus Communication Interface module, (FCI). The ModuleBus Optical ports are used together with the communication modules CI801 or CI840. TB842 is connected to CI801 through TB806 and to CI840 through TB806 and TU847 or TB846 and TU ,6 mm 42,3 mm 56,7 mm Figure 35. ModuleBus Optical Port TB BSE A

87 Section 2 Product Description ModuleBus Opto Connectors and Cables Local Optical Cable. Opto connectors type Agilent s, former Hewlett-Packard, Versatile Link can handle both plastic and HCS optic fibre. Plastic Optical Fiber (POF) up to 15 m. Extra low loss attenuation Simplex or duplex cable Latching simplex or duplex connector Cable attenuation maximum 4 db Hard Clad Silica (HCS) fiber up to 200 m Riser or plenum Simplex or duplex cable Latching simplex or duplex connector Cable attenuation maximum 2 db TB825 Field Optical Cable. Glass Optical Fiber, multimode up to 1000 m. Fiber dimensions: 62.5/125 µm Connector type: ST, bayonet Wave length: 820 nm Max cable attenuation: 3.5 db (1000 m of unspliced cable) TB826 Field Optical Cable. Glass Optical Fiber, single mode up to 5000m (20000m for S800 I/O HI) Fiber dimensions: 9/125 µm Connector type: SC Wave length: 1310 nm Max cable attenuation: 20 db 3BSE A 87

88 ModuleBus Section 2 Product Description ModuleBus Extension Cable Adaptors TB805, TB806 for single ModuleBus The ModuleBus extension cable adaptors exist in two types for bus outlet and bus inlet. The adaptors have two connectors for the electrical ModuleBus and for the ModuleBus extension cable. See Figure 36 on the next page. MTUs and S800L I/O modules within a cluster can be set up in two or more physically separated groups with extension cable adaptors which fit to the bus outlet and inlet connectors of communication interface modules, Optical ModuleBus Modem, MTUs and S800L modules. The factory made extension cables which plug into the cable adaptors are available in lengths of 0.3, 0.6 and 1.2 m (1, 2 or 4 ft.), allowing together with up to 12 I/O modules, for a total bus length of 2.5 m (8.2 ft.). Figure 36. ModuleBus Cable Inlet/Outlet 88 3BSE A

89 Section 2 Product Description ModuleBus ModuleBus Extension Cable Adaptors TB845, TB846 for dual ModuleBus The ModuleBus extension cable adaptors for dual electrical ModuleBuses exists in two types for ModuleBus outlet and ModuleBus inlet. The adaptors have two connectors for the electrical ModuleBus and two for the ModuleBus extension cable. See Figure 37 and Figure 38. MTUs within a cluster can be set up in two or more physically separated groups with extension cable adaptors which fit to the bus outlet and inlet connectors of communication interface modules, Optical ModuleBus Modem and MTUs. The factory made extension cables are available in lengths of 0.3, 0.6 and 1.2 m (1, 2 or 4 ft.), allowing together with up to 6 MTUs, for a total bus length of 2.5 m (8.2 ft.). 3BSE A 89

90 ModuleBus Section 2 Product Description Figure 37. Module Outlet Module TB BSE A

91 Section 2 Product Description ModuleBus Figure 38. ModuleBus Inlet Module TB846 3BSE A 91

92 C C B B ModuleBus Section 2 Product Description ModuleBus Terminator Module TB807 There must be a ModuleBus terminator module at the end of each electrical ModuleBus. ModuleBus Connector (X1) Top View 18 mm (0,71 ) 13 mm (0,52 ) 13 mm (0,52 ) TB mm (0,75 ) ModuleBus Terminator Latch E D F A E D F A MTU Assembly (0,52 ) L1+ C C8L2+ L1+ B B8L2+ L1- A A8L2- Figure 39. ModuleBus Terminator Module 92 3BSE A

93 Section 2 Product Description Power Supplies Power Supplies The power supplies SD831, SD832, SD833, and SD834(24 V output) can be used to power processor modules and S800 I/O modules, through the processor unit, and to power 24 V field circuits (optional). The primary side can connect to industrial mains installation class III (IEC664). SD83x is a switch-mode power supply unit which converts the mains voltage to 24 volts d.c. The outputs are protected and can operate with resistive, capacitive, and constant power loads. These power supplies can be utilized for non-redundant and redundant applications. Only SD834 can be used in parallel connection to increase output power, 2*SD834. Redundant applications require diode voting units SS823 or SS832. The voting unit SS823 has one power OK signal. Two SS823 can never be configured in parallel to achieve more current. SS832 can be used directly for load up to 10 A. For loads up to 20 A, two SS832 modules must be used. The signals can connect to the SA or SB inputs of the Communication interface module, or to an Optical ModuleBus Modem (to monitor power status in 1:1 redundant mains configurations.) In a parallel connections, the lifetime will decrease due to not perfect load sharing. To get a better load sharing the output voltage from the power supply units should be adjusted to the same value. Each power supply should be connected to the load via a cable of the same area and length as the others. The length should be > 1 m and the area not bigger than necessary. Table 9. Power Supplies Module Type SD822Z SD831 SD832 SD833 Description Power Supply 115/230 V a.c./24 V d.c. 5 A Rated insulation voltage 300 V. Power Supply 100/120 V a.c./24 V d.c. 3 A Rated insulation voltage 300 V. Power Supply 100/240 V a.c./24 V d.c. 5 A Rated insulation voltage 300 V. Power Supply 100/120 V a.c./24 V d.c. 10 A Rated insulation voltage 300 V. 3BSE A 93

94 Power Supplies Section 2 Product Description Module Type SD834 Power Supply 100/240 V a.c./24 V d.c. 20 A Rated insulation voltage 300 V. SS822Z Voting Device 20 A. Dual d.c. 24 V to single 24 V. Rated insulation voltage 50 V. SS823 SS832 Table 9. Power Supplies (Continued) Description Power Voting Unit 20A with overvoltage protection. Two units required for redundancy. Rated insulation voltage 50 V. Power Voting Unit 20A. Two units required for redundancy. Rated insulation voltage 50 V. 94 3BSE A

95 Section 2 Product Description Power Supplies Figure 40. Power Supply Module SD831 3BSE A 95

96 Power Supplies Section 2 Product Description Figure 41. Power Supply Module SD BSE A

97 Section 2 Product Description Power Supplies Figure 42. Power Supply Module SD833 3BSE A 97

98 Power Supplies Section 2 Product Description Figure 43. Power Supply Module SD BSE A

99 Section 2 Product Description Power Supplies Figure 44. Voting Unit SS823 3BSE A 99

100 Power Supplies Section 2 Product Description Figure 45. Voting Unit SS BSE A

101 Section 2 Product Description Mounting Equipment Mounting Equipment Mounting Kit for CI801/CI840/CI840A/TB840/TB840A The Mounting Kit is used for horizontal mounting of CI801/CI840/CI840A and TB840/TB840A on a vertical DIN-rail. This enables the higher range of the ambient temperature for CI801/CI840/CI840A and TB840/TB840A. Apart from MTUs for CI840, TB840 can also be ModuleBus cable adapters mounted on the Mounting Kit. Figure 46. Mounting Kit for CI801/CI840/CI840A/TB840/TB840A Table 10. Mounting Kit Dimensions Item Width 200 mm (7.87 ) Depth 170 mm (6.69 ) Height 17 mm (0.67 ) Weight 0.5 kg (1.10 lbs.) Value 3BSE A 101

102 Mounting Equipment Section 2 Product Description There are 9 different configuration alternatives for mounting of MTUs, see Figure 47. TU840/TU848 TB845 TU841/TU849 TB805 TU846 TB845 TU847 TB805 TB846 TU846 TB845 TB806 TU847 TB805 TU807 TB805 TB806 CI801 TB805 CI801 TB805 Figure 47. Configurations for mounting of MTUs on the Mounting Kit Prefabricated Aluminium Profile Prefabricated aluminium profile for mounting of S800 I/O modules in cabinets or other types of installations. The profile supports good mechanical stability and chassis ground connection. There are aluminium profiles for horizontal 465 mm (19 ), 592 mm (24 ) or 719 mm (28.31 ) mounting, see Figure BSE A

103 Section 2 Product Description Mounting Equipment Screws for fastening in environments with high vibrations Groove for fastening screws Figure 48. MTU mounted on aluminium profile The profile has grooves for self-tapping screws (ST ) that can be used for fastening the modules in an environment with high vibrations. The aluminum profiles have one DIN-rail and one cable duct and are available in different sizes. 3BSE A 103

104 Mounting Equipment Section 2 Product Description 7.73 mm (0.29") 482 mm (19") 465 mm (18.31") 40 mm (1.57") mm (1.75") mm (9.97") 76 mm (2.99") Figure 49. Prefabricated Aluminium Profile Dimensions 104 3BSE A

105 Section 2 Product Description G3 compliant modules G3 compliant modules In general, all S800 units are G3 compliant (for exceptions, see Product Overview on page 24). The G3 compliant units withstand more severe environmental conditions according to ISA-S During transport, storage and installation special caution must be taken: Dividable connectors/terminals must not be left unconnected/open in G3 environment if they are intended to be used later. Modules must not be stored in G3 environment due to unprotected connectors/terminals, also valid for modules in packaging. I/O Station Configurations An I/O station can consist of one Base I/O cluster and up to seven I/O clusters. The Base I/O cluster consists of a FCI, single or redundant, and up to 12 I/O modules. The I/O cluster consists of one ModuleBus Modem and up to 12 I/O modules. For I/O station with single FCI for PROFIBUS or AF100, and redundant FCI for AF100, see Figure 50. Both PROFIBUS and AF100 have non-redundant ModuleBus Extension. For I/O station with redundant FCIs, and for PROFIBUS with non-redundant ModuleBus Extension, see Figure 51. For I/O cluster connected to controller AC800M, via redundant ModuleBus Extension, see Figure 52. Redundant ModuleBus Extension can only be used together with AC800M. Redundant I/O can only be configured in the base cluster. 3BSE A 105

106 I/O Station Configurations Section 2 Product Description TB 806 ModuleBus Cable Adaptor-In TB 807 ModuleBus Terminator CI810 FCI CI820 FCI Base I/O Cluster Optical ModuleBus Port TB810 TB815 Interconnection Unit Optical ModuleBus Port TB810 Base I/O Cluster I/O Cluster 1 ModuleBus Modem TB820 I/O Cluster 1 ModuleBus Modem TB820 I/O Cluster 2 I/O Cluster 2 I/O Cluster 3 I/O Cluster 3 Figure 50. Optical ModuleBus Extension from CI810, CI BSE A

107 Section 2 Product Description I/O Station Configurations TB806/TB846 CI840 Base I/O Cluster TB807 TB842 TU846/TU847 I/O Cluster 1 ModuleBus Modem TB820 I/O Cluster 2 I/O Cluster 3 Figure 51. Optical ModuleBus Extension from CI840 3BSE A 107

108 I/O Station Configurations Section 2 Product Description Redundant AC800M TB840 I/O Cluster TB807 TU841 Figure 52. Optical ModuleBus Connection to Redundant TB BSE A

109 Section 2 Product Description Mounting Mounting The I/O station can be mounted horizontally, vertically or in combinations (Figure 53 to Figure 57). Compact or Extended MTUs or S800L modules can be used depending on available space and preferred way of installing the field wiring (external marshalling/power distribution or direct on Extended MTUs using built in 2/3 wire termination and power distribution arrangements). Compact and Extended MTUs as well as S800L modules can be mixed and matched within the I/O station to suit the required field termination. The S800 I/O is mounted on a DIN-rail. The DIN-rail is mounted in a cabinet or on an enclosure wall to a metal sheet with fastening screws every 100 mm to ensure a good chassis ground connection in the cabinet or on an open track. The FCI, ModuleBus Modem, MTUs and S800L I/O modules are mounted on the DIN-rail. It is recommended to use end supports when mounting the I/O station. In environments with major vibrations, the MTUs shall be screwed on the metal sheet. 162mm (6.37 ) 826 mm (32.5 ) 20mm (0.8 ) Terminator TB807 84mm 58.5 mm (3.3 ) (2.3 ) Figure 53. Horizontal Mounting of 1 FCI (left) and 12 S800M I/O MTUs (Compact) 1540mm (60.6 ) 84mm 120mm (3.3 ) (4.72 ) Terminator TB807 Figure 54. Horizontal Mounting of 1 FCI (left) and 12 S800M I/O MTUs (Extended) 3BSE A 109

110 Mounting Section 2 Product Description 1169 mm (46 ) 162mm (6.37 ) S Status S Status S Status S Status 110mm (4.33 ) 84mm 58mm (3.3 ) (2.3 ) 85.8 mm (3.4 ) 120 mm (4.72 ) Terminator TB807 Figure 55. Mixed Mounting of 1 FCI and S800M I/O MTUs (Compact and Extended) and S800L I/O Modules By using extension cable(s) a very flexible mounting arrangement is possible, adapting to required panel or cabinet layout. The maximum length of an electrical ModuleBus should not be more when 2.5 m (100 ) Terminator TB807 Analog Inputs TK801V0xx Digital Inputs Cable Adaptor, out TB805 S Status Cable Adaptor, in TB806 Analog Outputs Digital Outputs Figure 56. I/O Station in Small Groups 110 3BSE A

111 Section 2 Product Description Mounting In I.S. applications, modules with I.S. Interfaces MUST be mounted right most of the I/O station or as a separate group. The installation must be performed by qualified personnel. It must comply with the relevant national/international standards (e.g. IEC 79-14, CEI 64-2, BS 5345 Pt. 4, DIN VDE 165) and in-line with the established installation rules and recommended practice (e.g. CEI 64-8, ANSI/ISA RP-12.6). The conformity of hazardous area field devices with the related system documentation must always be checked. When using modules with I.S. Interfaces in non I.S.applications, the I.S. modules can be placed in any position following the same rules as non I.S. modules. 3BSE A 111

112 Mounting Section 2 Product Description 162mm (6.37 ) 162mm (6.37 ) 84mm (3.3 ) 123mm (4.83 )* 120mm (4.72 ) 84mm (3.3 ) 58mm (2.3 ) 796mm (31.3 ) 1540mm (60.6 ) 1579mm (62.2 )* 20mm (0.8 ) 20mm (0.8 ) 110mm (4.33 ) * Measurement for TU847 and CI840 Figure 57. Vertical Mounting of S800M I/O MTUs 112 3BSE A

113 Section 2 Product Description Mounting Terminator TB mm (6.84 ) CI820 FCI 162mm (6.36 ) TK801V0xx TB815 Interconnection Unit Cable adaptor, out Cable adaptor, in TB805 TB806 Figure 58. I/O Station with Redundant CI820 FCIs 3BSE A 113

114 Mounting Section 2 Product Description 84 mm (3.3 ) 123 mm (4.83 )* * mm (16 )* mm (14.4 ) mm (0.87 ) Status Status S S mm (3.4 ) 162 mm (6.38 ) Status S Status S Status S Status Status Status Status Status Status Status Status Status Status S S S S S S S S S S mm 1143 mm (45 ) 1182 mm (46.5 )* Bus Cable Length = 300 mm (11.8 ) mm (inch) Status Status Status Status Status Status Status Status Status S S S S S S S S S mm (0.87 ) (3.4 ) 85.8 mm mm (32.3 ) (0.8 ) 110 mm (4.3 ) 20 mm (0.8 ) * Measurements for TU847 and CI840 Figure 59. Maximum Layout of I/O Cluster with S800L 114 3BSE A

115 Section 2 Product Description Mounting 3BSE A 115

116 Mounting Section 2 Product Description 116 3BSE A

117 Section 3 Technical Data and Performance Directives EMC Directive All products, mentioned in this document, that bares the CE marking, meet the requirement of the EMC Directive EMCD 2004/108/EC. The following standards have been applied: EN (2007) EMC, Emission EN (2005) EMC, Immunity Low Voltage Directive All products, mentioned in this document, that bares the CE marking, meet the requirement of the Low Voltage Directive LVD 2006/95/EC. The following standard has been applied: EN (2007) Clause 11, 12, 13 and 14. ATEX directive All products, mentioned in this document, that bares the Ex symbol, meet the requirement of the ATEX Directive ATEX 94/9/EC. For more information, see Certifications on page BSE A 117

118 Standards and Approvals Section 3 Technical Data and Performance Standards and Approvals It is important to check how the approvals are applicable for each module. Electrical Safety Table 11. Electrical Safety EN IEC/EN (Clause 11, 12, 13 and 14) UL 508 CSA 22.2 No.142-M1987 Electronic Equipment for Use in Power Installations Programmable Controllers Part 2: Equipment Requirements and Tests Industrial Control Equipment. Process Control Equipment. Industrial Products Hazardous Classified Locations CSA 22.2 No.213-M1987 CAN/CSA-E :02 FM 3600 FM 3611 UL Table 12. Hazardous Locations Non-Incendive Electrical Equipment for use in Class 1, Division 2 Hazardous Locations Electrical Equipment for use in Hazardous (Classified) locations Non-Incendive Electrical Equipment for use in Class 1, Division 2 Hazardous Locations Electrical Apparatus for Explosive Gas Atmospheres - Part 15: Electrical Apparatus with Type of Protection "n". IEC/EN Electrical apparatus for explosive gas atmospheres Part 15: Construction, test and marking of type of protection n electrical apparatus. EN Electrical apparatus for potentially explosive atmospheres - Intrinsic safety "i" See Certifications on page 169 for each module type certification details BSE A

119 Section 3 Technical Data and Performance CE-marking CE-marking G3 Compliant The S800 products fulfill the requirements of EU-directives 2004/108/EC "Electromagnetic Compatibility" (EMC Directive) and 2006/95/EC "Electrical Equipment Designed for Use between Certain Voltage Limits" (Low Voltage Directive). The declarations of conformity are available on request. See Certifications on page 169 for each module type certification details. The G3 compliant modules fulfills the severity level in the standard ISA-S71.04 Environmental Conditions for Process Measurement and Control Systems: Airborne Contaminants. The G3 compliant modules shall not be stored in more severe environment than G2 if the contacts are unconnected. Transport and Storage Conditions The S800 modules should be transported and stored in their original packaging. Table 13. S800 Storage Conditions Condition Range Standard Temperature -40 to +70 C IEC/EN Humidity Altitude RH = 5 to 95%, no condensation -500 to m Pollution degree Degree 2 IEC Corrosive atmosphere < 1000 Angstrom copper corrosion over 28 days ISA Severity level G2 3BSE A 119

120 Transport and Storage Conditions Section 3 Technical Data and Performance Table 13. S800 Storage Conditions Condition Range Standard Fall in package Shock < 10 kg: 300 mm kg: 300 mm > 40 kg: 250 mm Free-fall drop height in original product package. 150 m/s 2, 11 ms IEC/EN BSE A

121 Section 3 Technical Data and Performance Climatic Operating Conditions Climatic Operating Conditions Table 14. Climatic Operating Conditions Condition Operative range Standard Temperature (1) Temperature change Humidity Altitude 0 to +55 C non-condensing 0 to +40 C compact MTUs or S800L modules on vertical DIN-rail, see Table 32, non-condensing 3 C/min RH = 5 to 95%, no condensation 2000 m IEC/EN Pollution degree Degree 2 IEC Corrosive atmosphere <1000 Angstrom copper corrosion over 28 days <2000 Angstrom copper corrosion over 28 days ISA Severity level G2 ISA Severity level G3 (1) Approvals are issued for +5 to +55 C. Mechanical Operating Conditions Table 15. Mechanical Operating Conditions Vibration Test Sinusoidal Operational Operative range 5 9 Hz, amplitude 3,5 mm Hz, acceleration 1,0g 1 octave/min Standard IEC/EN Shock 150 m/s 2, 11 ms IEC/EN Emitted noise <55 db (A) 3BSE A 121

122 EMC Section 3 Technical Data and Performance EMC Table 16. Radiated Radio Frequency Emission IEC/EN (Class A), IEC/EN Radiated Radio Frequency Emission IEC/EN (Class A), IEC/EN Test Limits 30 MHz -230 MHz 40 db (µv/m) quasi peak measured at 10m 230 MHz MHz 47 db (µv/m) quasi peak measured at 10m Generic standards EN/IEC , EN/IEC Table 17. Conducted Radio Frequency Emission, AC mains port IEC (Class A), IEC/EN Conducted Radio Frequency Emission, AC mains port IEC (Class A), IEC/EN Test 0,15 MHz -0,50 MHz Limits 79 db (µv/m) quasi peak 66 db (µv/m) average 0,50 MHz - 30 MHz 73 db (µv) quasi peak 60 db (µv/m) average Generic standards EN/IEC , EN/IEC BSE A

123 Section 3 Technical Data and Performance EMC Table 18. Immunity IEC/EN , IEC/EN Immunity IEC/EN , IEC/EN Continuous... Test Radiated RF field Severity 80MHz 1.0GHz, 10 V/m 1.4GHz 2.0GHz, 3 V/m 2.0GHz 2.7GHz, 1 V/m Generic standards EN/IEC , EN/IEC Conducted RF field 0.15MHz-80MHz, 10V EN/IEC , EN/IEC Table 19. Transients Immunity Transients immunity Electrostatic discharge Electrical fast transient/burst Surge 4 kv contact discharge 8 kv air discharge 2 kv, AC/DC, process I/O AC 1 kv, Process I/O DC, analog I/O and com 2 kv common mode, AC/DC power ports, process I/O AC 1 kv differential mode, Process I/O DC, analog I/O and com IEC , IEC IEC , IEC IEC , IEC BSE A 123

124 Overvoltage Categories Section 3 Technical Data and Performance Overvoltage Categories Table 20. Overvoltage Installation type Category Standards Equipment permanently connected to low voltage mains Equipment not energized directly from the low voltage mains Overvoltage categories III IEC/EN Overvoltage categories II AC mains power supplies are compliant with Overvoltage Category III networks (industrial mains). All I/O signals are overvoltage II compliant. Equipment Class and Insulation Voltages Equipment Class The S800 equipment class is Class 1 according to IEC Class 1 means protection of electric shock by protective earth connection (PE). In this case this means a PE- connection must be made to the DIN-rail. Insulation Voltage All accessible ports on S800 modules are galvanically isolated from ground and system. For actual module isolation configuration, consult module data sheets BSE A

125 Section 3 Technical Data and Performance Insulation Test Voltage Insulation Test Voltage Type test, insulation test voltage 500 V a.c. or 700 V d.c. 1 minute for RIV 50V 1 modules 2000 V a.c. 1 minute for RIV 250V modules Routine Test, insulation test voltage 850 V d.c. 1 second for RIV 50V modules 2000 V a.c. 1 second for RIV 250V modules 1. Modules with a working voltage of less than 50 V have RIV 50 V. RIV 250 V applies to all modules having a working voltage greater than 50 V. It should be noted that insulation test voltage specifications, according to electrical safety standards, do not imply that permanent connection to circuits with voltages greater than the specified Rated Insulation Voltage is allowed. Connection to voltages higher than specified RIV violates electrical safety codes and may expose users to electric shock. 3BSE A 125

126 Capacity and Performance Section 3 Technical Data and Performance Capacity and Performance Advant Fieldbus 100 Load The bus load is calculated with different figures according to the bus length: for bus length max 2000 m (2200 yards), use Table 21 for bus length max 8500 m (9300 yards), use Table 22 for bus length max m (16400 yards), use Table 23. To calculate the bus load in percent (AF100%load), at the required Cycle Time, the CI810/CI820 (FCI) loading per station and the I/O Module Type quantity times the per cent loading. For bus load calculation, use the formula: AF100 %load = CI810/CI820 load + S800 I/O Module 1 load + S800 I/O Module n load +... Calculation of load for AF100 with a length of max 2,000 m (2,200 yards) Due to the organization of the Advant Fieldbus 100 scans, some constraints are imposed on the transmissions. To guarantee message transfer etc., at least 30% of the fieldbus load is reserved. The remaining load (up to 70%) can be used for S800 I/O station loading and other station loading. The calculated load of Advant Fieldbus 100 must be equal to or less than 70%. Below is an example for an I/O station with one CI810 FCI, 2 AI810s, two AO810/AO810V2s, four DI810s and four DO810s using 128ms cycle time for AI and AO modules and 64ms for DI and DO modules: AF100 %load = 0.033% + (2 x 0.197% AI810 ) + (2 x 0.221% AO810/AO810V2 ) + (4 x 0.138% DI810 ) + (4 x 0.146% DO810 ) = 2.005% Load 126 3BSE A

127 Section 3 Technical Data and Performance Advant Fieldbus 100 Load Table 21. % of load on the Advant Fieldbus 100 by S800 I/O (up to 2000 m Bus Length) Module Type Cycle Time (ms) AI801 AI810 AI890 AI895 AI820 AI830 AI830A AI835 AO801 AO810 AO810V2 AO890 AO895 AO820 DI801, DI802 DI803, DI810 DI811, DI814 DI820, DI821 DI830, DI831 DI885, DI890 DO801 (1), DO802 DO810 (1), DO814 (1), DO815 (1), DO820 (1), DO821 (1), DO890 (1) DP820 (2) INSCANT DP820 (2) OUT- SCANT % 15.6% 25.3% 25.23% 15.62% 8.8% 8.8% 25.2% 15.6% % 7.8% 12.6% 12.63% 7.815% 4.4% 4.4% 12.6% 7.8% 4 6.3% 3.9% 6.3% 6.325% 3.915% 2.2% 2.2% 6.3% 3.9% % 1.95% 3.15% 3.175% 1.965% 1.1% 1.1% 3.15% 1.95% % 0.975% 1.575% 1.6% 0.99% 0.55% 0.55% 1.575% 0.975% % 0.488% 0.788% 0.812% 0.503% 0.275% 0.275% 0.788% 0.488% % 0.244% 0.394% 0.418% 0.259% 0.138% 0.138% 0.394% 0.244% % 0.122% 0.197% 0.221% 0.137% 0.069% 0.069% 0.197% 0.122% % 0.061% 0.098% 0.123% 0.076% 0.034% 0.034% 0.098% 0.061% % 0.03% 0.049% 0.074% 0.046% 0.017% 0.017% 0.049% 0.030% % 0.015% 0.025% 0.049% 0.03% 0.009% 0.009% 0.025% 0.015% % 0.008% 0.012% 0.037% 0.023% 0.004% 0.004% 0.012% 0.008% % 0.004% 0.006% 0.031% 0.019% 0.002% 0.002% 0.006% 0.004% (1) Readbacks increase the load depending on the cyclicity and with the same amount as the net load at the cycle time. For Master the cycle time is 1024 which gives 0.009% more load. For MOD the cycle time is configurable. (2) Total load = (load generated by INSCANT) + (load generated by OUTSCANT) The total load if INSCANT is 32 ms and OUTSCANT is 64 ms is: Total load = = 1.032% 3BSE A 127

128 Advant Fieldbus 100 Load Section 3 Technical Data and Performance Calculation of load for AF100 with a length of max 8,500 m (9,300 yards) Due to the organization of the Advant Fieldbus 100 scans, some constraints are imposed on the transmissions. To guarantee message transfer etc., at least 50% of the fieldbus load is reserved. The remaining load (up to 50%) can be used for S800 I/O station loading and other station loading. The calculated load of Advant Fieldbus 100 must be equal to or less than 50%. NOTE! 1 ms cycle time is not allowed. Cycle Time (ms) Table 22. % of load on the Advant Fieldbus 100 by S800 I/O (8,500 m Bus Length) AI801 AI810 AI890 AI895 AI820 AI830 AI830A AI835 AO801 AO810 AO810V2 AO890 AO895 AO820 Module Type DI801, DI802 DI803, DI810 DI811, DI814 DI820, DI821 DI830, DI831 DI885, DI890 DO801 (1), DO802 (1) DO810 (1) DO814 (1), DO815 (1) DO820 (1), DO821 (1) DO890 (1) DP820 (2) INSCANT DP820 (2) OUT- SCANT % 11.80% 16.60% 16.63% 11.82% 8.40% 8.40% 16.60% 11.80% % 5.900% 8.300% 8.332% 5.923% 4.200% 4.200% 8.300% 5.900% % 2.950% 4.150% 4.182% 2.973% 2.100% 2.100% 4.150% 2.950% % 1.475% 2.075% 2.107% 1.498% 1.050% 1.050% 2.075% 1.475% % 0.738% 1.038% 1.070% 0.761% 0.525% 0.525% 1.038% 0.738% % 0.369% 0.519% 0.551% 0.392% 0.263% 0.263% 0.519% 0.369% % 0.184% 0.259% 0.292% 0.207% 0.131% 0.131% 0.259% 0.184% % 0.092% 0.130% 0.162% 0.115% 0.066% 0.066% 0.130% 0.092% % 0.046% 0.065% 0.097% 0.069% 0.033% 0.033% 0.065% 0.046% % 0.023% 0.032% 0.065% 0.046% 0.016% 0.016% 0.032% 0.023% % 0.012% 0.016% 0.049% 0.035% 0.008% 0.008% 0.016% 0.012% % 0.006% 0.008% 0.041% 0.029% 0.004% 0.004% 0.008% 0.006% (1) Readbacks increase the load depending on the cyclicity and with the same amount as the net load at the cycle time. For Master the cycle time is 1024 which gives 0.016% more load. For MOD the cycle time is configurable. (2) Total load = (load generated by INSCANT) + (load generated by OUTSCANT) The total load if INSCANT is 32 ms and OUTSCANT is 64 ms is: Total load = = 1.407% 128 3BSE A

129 Section 3 Technical Data and Performance Advant Fieldbus 100 Load Calculation of load for AF100 with a length of max 15,000 m (16,400 yards) Due to the organization of the Advant Fieldbus 100 scans, some constraints are imposed on the transmissions. To guarantee message transfer etc., at least 50% of the fieldbus load is reserved. The remaining load (up to 50%) can be used for S800 I/O station loading and other station loading. The calculated load of Advant Fieldbus 100 must be equal to or less than 50%. NOTE! 1 ms cycle time is not allowed. Cycle Time (ms) Table 23. % of load on the Advant Fieldbus 100 by S800 I/O (15,000 m Bus Length) AI801 AI810 AI890 AI895 AI820 AI830 AI830A AI835 AO801 AO810 AO810V2 AO890 AO895 AO820 Module Type DI801, DI802 DI803, DI810 DI811, DI814 DI820, DI821 DI830, DI831 DI885, DI890 DO801 (1), DO802 DO810 (1), DO814 (1), DO815 (1), DO820 (1), DO821 (1), DO890 (1) DP820 (2) INSCANT DP820 (2) OUT- SCANT % 15.80% 20.60% 20.64% 15.83% 12.40% 12.40% 20.60% 15.80% % 7.900% 10.30% 10.34% 7.931% 6.200% 6.200% 10.30% 7.900% % 3.950% 5.150% 5.190% 3.981% 3.100% 3.100% 5.150% 3.950% % 1.975% 2.575% 2.615% 2.006% 1.550% 1.550% 2.575% 1.975% % 0.988% 1.288% 1.328% 1.018% 0.775% 0.775% 1.288% 0.988% % 0.494% 0.644% 0.684% 0.525% 0.388% 0.388% 0.644% 0.494% % 0.247% 0.322% 0.362% 0.278% 0.194% 0.194% 0.322% 0.247% % 0.123% 0.161% 0.201% 0.154% 0.097% 0.097% 0.161% 0.123% % 0.062% 0.080% 0.121% 0.093% 0.048% 0.048% 0.080% 0.062% % 0.031% 0.040% 0.080% 0.062% 0.024% 0.024% 0.040% 0.031% % 0.015% 0.020% 0.060% 0.046% 0.012% 0.012% 0.020% 0.015% % 0.008% 0.010% 0.050% 0.039% 0.006% 0.006% 0.010% 0.008% (1) Readbacks increase the load depending on the cyclicity and with the same amount as the net load at the cycle time. For Master the cycle time is 1024 which gives 0.009% more load. For MOD the cycle time is configurable. (2) Total load = (load generated by INSCANT) + (load generated by OUTSCANT) The total load if INSCANT is 32 ms and OUTSCANT is 64 ms is: Total load = = 1.782% 3BSE A 129

130 PROFIBUS CI801 Section 3 Technical Data and Performance PROFIBUS CI801 Number of S800 I/O Stations Maximum number of S800 I/O stations per bus: 99 stations Supported communication speeds: 9.6 kbit/s to 12 Mbit/s Maximum number of S800 I/O stations per Profibus bus segment: 32 stations. Maximum number of S800 I/O modules in a station: 24 modules Maximum number of S800 I/O modules per cluster: 12 modules It is not allowed to physically install more than 12 MTUs and/or S800L modules in a cluster BSE A

131 Section 3 Technical Data and Performance PROFIBUS CI801 Calculation of Number of S800 I/O Modules per Station Due to the PROFIBUS-DP specification it is not possible to always connect 24 I/O modules to one FCI. This is because the S800 I/O system includes more data and user parameters than PROFIBUS-DP can handle. Table 24 shows maximum number of modules that can be connected to one CI801. Table 24. Maximum Number of Modules on CI801 Module Type AI801, AI810, AI830, AI830A, AI835, AI835A, AI890, AI893, AI895 Number of Modules 14 (11) AI820, AI (22) AI (9) AI815, AI (11) AO801, AO810, AO810V2, AO890, AO895 7 (5) AO (11) AO815, AO845, AO845A 7 (5) DI801, DI802, DI803, DI810, DI811, DI820, DI (24) DI (24) DI (24) DI (16) DO801, DO810, DO (21) DO (13) DO802, DO815, DO820, DO (24) DO (21) DO (19) DP820 8 (6) 3BSE A 131

132 PROFIBUS CI801 Section 3 Technical Data and Performance Table 24. Maximum Number of Modules on CI801 (Continued) Module Type Number of Modules DP840 7 (5) Standard Drives 9 (7) The values in brackets are in Extended HART mode and HCIR. In order to find out if a given configuration of analog and digital modules can be used, the following method should be used: Fill in number of modules in Table 25. Calculate the sum in the three columns: Sum User Parameters Sum Input Bytes Sum Output Bytes Calculate the three total sums for: ParamSize InSize OutSize. Check that: ParamSize is less than or equal to 221 (220 if HCIR is used) InSize is less than or equal to 239 in normal mode, 199 in Extended HART mode OutSize is less than or equal to 112 in normal mode, 90 in Extended HART mode If any of these three values is too high then the configuration can not be used BSE A

133 Section 3 Technical Data and Performance PROFIBUS CI801 Table 25. Calculation of Number of Modules on CI801 Module Type User Parameters Input Bytes Output Bytes Number of Modules Sum User Parameters Sum Input Bytes Sum Output Bytes AI AI AI AI AI830/ AI830A AI AI835A AI AI815, AI AI AI AI AO AO810/ AO810V AO AO815, AO845/ AO845A AO AO BSE A 133

134 PROFIBUS CI801 Section 3 Technical Data and Performance Table 25. Calculation of Number of Modules on CI801 (Continued) Module Type User Parameters Input Bytes Output Bytes Number of Modules Sum User Parameters Sum Input Bytes Sum Output Bytes DI DI DI DI DI DI DI DI DI DI DI DI DO DO DO DO DO DO DO820/ DO DO DO BSE A

135 Section 3 Technical Data and Performance PROFIBUS CI801 Module Type DO DP DP Standard Drives Table 25. Calculation of Number of Modules on CI801 (Continued) User Parameters Input Bytes Output Bytes Number of Modules Sum User Parameters Sum Input Bytes Sum Output Bytes Total sum ParamSize InSize OutSize Calculation of Bus Cycle Time How to calculate the Bus Cycle Time, see documentation for current master. To calculate the Bus Cycle Time the following parameters for the I/O station shall be used: Number of input and output bytes. See Calculation of Number of S800 I/O Modules per Station on page 131. MAX T SDR Maximum Station Delay of Responder in T BIT (Bit Time). See GSD file. 3BSE A 135

136 PROFIBUS CI840 Section 3 Technical Data and Performance PROFIBUS CI840 Number of S800 I/O Stations Maximum number of S800 I/O stations per bus: Redundant CI840: 62 stations. Single CI840: 99 stations Supported communication speeds: kbit/s to 12 Mbit/s Maximum number of S800 I/O stations per PROFIBUS segment: Communication speed 12 Mbit: 20 stations. Communication speed 1,5 Mbit: 32 stations. Maximum number of S800 I/O modules in a station: 24 modules Maximum number of S800 I/O modules per cluster: 12 modules Switch over time at failure in a redundant CI840 configuration is typical <100 ms and maximum 150 ms. The 12 modules per cluster can either be 12 single I/O modules or 6 pairs of redundant I/O modules. Redundant I/O modules can only be mounted on the base cluster. It is not allowed to mix single and redundant I/O modules within a cluster. It is not allowed to physically install more than 12 single MTUs and/or S800L modules in a single cluster. It is also not allowed to physically install more than 6 redundant MTUs in a redundant cluster BSE A

137 Section 3 Technical Data and Performance PROFIBUS CI840 Calculation of Number of S800 I/O Modules per Station Due to the PROFIBUS-DP specification it is not possible to connect 24 analog I/O modules to one FCI. The reason is that the S800 I/O system includes more data and user parameters than PROFIBUS-DP can handle. Table 26 shows maximum number of modules that can be connected to one CI840. Table 26. Maximum Number of Modules on CI840 Module Type AI801, AI810, AI815, AI830, AI830A, AI835, AI835A, AI890, AI893, AI895 Number of Modules 14 (11) AI820, AI (22) AI (9) AI (11) AO801, AO810, AO815, AO810V2, AO845, AO845A, AO890, AO895 7 (5) AO (11) DI801, DI802, DI803, DI810, DI811, DI820, DI821, DI825 (1), DI (24) DI (24) DI (24) DI830 (1), DI831 (1) 15 (15) DI (16) DI885 (1) 22 (21) DO801, DO810, DO (21) DO802, DO815, DO820, DO (24) 3BSE A 137

138 PROFIBUS CI840 Section 3 Technical Data and Performance Table 26. Maximum Number of Modules on CI840 (Continued) Module Type Number of Modules DO (13) DO (21) DO (19) DP820 8 (6) DP840 7 (5) (1) Not supported by AC 800M The values in brackets are in Extended HART mode and HCIR BSE A

139 Section 3 Technical Data and Performance PROFIBUS CI840 In order to find out if a given configuration of analog and digital modules can be used, the following method should be used: Fill in number of modules in Table 27. Calculate the sum in the three columns: Sum User Parameters Sum Input Bytes Sum Output Bytes Calculate the three total sums for: ParamSize InSize OutSize. Check that: ParamSize is less than or equal to 221 (220 if HCIR is used) InSize is less than or equal to 239 in normal mode, 199 in Extended HART mode OutSize is less than or equal to 112 in normal mode, 90 in Extended HART mode If any of these three values is too high then the configuration can not be used. 3BSE A 139

140 PROFIBUS CI840 Section 3 Technical Data and Performance Table 27. Calculation of Number of Modules on CI840 Module Type User Parameters Input Bytes Output Bytes Number of Modules Sum User Parameters Sum Input Bytes Sum Output Bytes AI AI AI AI AI830/ AI830A AI AI835A AI AI845/ AI AI AI AI AO AO810/ AO810V AO AO815/ AO845/ AO845A AO AO BSE A

141 Section 3 Technical Data and Performance PROFIBUS CI840 Table 27. Calculation of Number of Modules on CI840 (Continued) Module Type User Parameters Input Bytes Output Bytes Number of Modules Sum User Parameters Sum Input Bytes Sum Output Bytes DI DI DI DI DI DI DI DI DI DI DI825 (1) DI830 (1) DI831 (1) DI DI885 (1) DI DO DO DO DO DO DO BSE A 141

142 PROFIBUS CI840 Section 3 Technical Data and Performance Module Type DO820/ DO821 Table 27. Calculation of Number of Modules on CI840 (Continued) User Parameters Input Bytes Output Bytes DO DO DO DP DP Number of Modules Sum User Parameters Sum Input Bytes Sum Output Bytes Total sum ParamSize InSize OutSize (1) Not supported by AC 800M 142 3BSE A

143 Section 3 Technical Data and Performance S800 I/O Station Data Scanning Calculation of Bus Cycle Time How to calculate the Bus Cycle Time, see documentation for current master. To calculate the Bus Cycle Time the following parameters for the I/O station shall be used: Number of input and output bytes. MAX T SDR Maximum Station Delay of Responder in T BIT (Bit Time). See GSD file. S800 I/O Station Data Scanning The ModuleBus data is scanned (read or written) cyclically, depending on the I/O module configuration. To calculate the I/O scan cycle time in the FCI do as follows: Totalize (number of module type x) * (used execution time for type x) (see Table 28) if the value is a multiple of 2, add 2 to the value. Otherwise increase the total value to the nearest higher multiple of 2 to get the I/O scan cycle time. If CI810A or C1810B is used, the scan cycle time is increased by 25% and for CI820 it is increased by 50%. If the value is a multiple of 2, add 2 to the value. Otherwise increase the value to the nearest higher multiple of 2, to get the I/O cycle time. Table 28. I/O Scan Cycle Time in the FCI Module Type CI801 Execution Time Used in ms CI810, CI820 CI840 Single I/O Redundant I/O pair AI801, AI810, AI890, AI AI AI AI830, AI830A, AI835, AI835A AI BSE A 143

144 S800 I/O Station Data Scanning Section 3 Technical Data and Performance Table 28. I/O Scan Cycle Time in the FCI (Continued) Module Type AI AI815, AI AO801, AO810, AO810V2, AO890, AO AO AO815, AO845, AO845A DI801, DI810, DI811, DI814, DI820, DI821, DI DI DI802, DI803, DI DI DI830, DI831, DI DO801, DO810, DO814, DO815, DO820, DO82 CI801 Execution Time Used in ms CI810, CI820 CI840 Single I/O Redundant I/O pair DO DO802, DO DO DO DP DP Engineered drives BSE A

145 Section 3 Technical Data and Performance S800 I/O Station Data Scanning Table 28. I/O Scan Cycle Time in the FCI (Continued) Module Type CI801 Execution Time Used in ms CI810, CI820 CI840 Single I/O Redundant I/O pair Standard drives FCI CI FCI CI FCI CI820 redundant FCI CI Analog modules will be scanned every fourth I/O scan cycle time except for AI830/AI830A, AI835, AI843 and AI893 modules which will be scanned every tenth time. DI and DO modules will be scanned each I/O scan cycle time. For example, a non-redundant station with a CI810A, two AO810/AO810V2, three DI810, two AI810, three DO810, two AI830/AI830A and one DP820 will give the following I/O scan cycle time: 1 CI810A => 1*1.40 ms = AO810/AO810V2 => 2*1.20 ms = DI810 => 3*0.43 ms = AI810 => 2*3.00 ms = DO810 => 2*0.43 ms = AI830/AI830A => 2*0.40 ms = DP820 => 1*1.72 ms = ms 14.9 ms is not a multiple of 2, so an increase of the value to the nearest multiple of 2 gives 16 ms. CI810A/CI810B compensation 1.25*16 ms=20 ms. 3BSE A 145

146 S800 I/O Station Data Scanning Section 3 Technical Data and Performance 20 ms is a multiple of 2, so add 2 to the value = BSE A

147 Section 3 Technical Data and Performance S800 I/O Station Data Scanning That will give an I/O scan cycle time of 22 ms between the FCI and its I/O modules. This means that the DIs and DOs will be scanned every 22 ms, the AI810s and the AO810/AO810V2 every (4*22 ms) 88ms and the AI830/AI830A every (10*22 ms) 220 ms. Minimum I/O scan cycle time = 4 ms single FCI (CI810) with firmware 1.0 to 1.2 Minimum I/O scan cycle time = 6 ms redundant FCI (CI820) with firmware 1.3 or later. For example, a redundant station with CI840, two AI810, one AO810/AO810V2, two DI810, two DO820 and one AI830/AI830A will give the following I/O scan cycle time: 2 AI810 => 2*3.00 ms = 6.00 ms 1 AO810/AO810V2 => 1*1.20 ms = 1.20 ms 2 DI810 => 2*0.50 ms = 1.00 ms 2 DO810 => 2*0.50 ms = 1.00 ms 1 AI830/AI830A => 1*0.40 ms = 0.40 ms 1 CI840 => 1*2.10 ms = 2.10 ms ms 11.7 ms is not a multiple of 2, so increase of the value to the nearest multiple of 2 gives 12 ms. That will give an I/O scan cycle time of 12 ms between the FCI and its I/O modules. This means that the DIs, DOs, DPs and Standard Drives will be scanned every 12 ms, the AIs and AOs every (4*12 ms) 48 ms and the AI830/AI830A, AI835, AI843 and AI893 every (10*12 ms) 120 ms. Minimum I/O scan cycle time = 4 ms. 3BSE A 147

148 Calculation of Maximum Distance of an Optical ModuleBus Configuration Section 3 Technical Data Calculation of Maximum Distance of an Optical ModuleBus Configuration Calculation of Maximum Fibre length for TB825 The maximum signal delay should be calculated in the configuration using Optical ModuleBus Media Converter. This is calculated using the signal path from the controller to the point in the configuration that has the longest delay. The maximum delay in an optical ModuleBus configuration must be 100µs (less than 250µs for S800 I/O HI). The delay values in Table 29 can be used to calculate the maximum delay in an optical ModuleBus configuration. Table 29. Delay Values Optical ModuleBus Components Opto-to-opto delay in TB825 (1) 2.4 µs Opto-to-opto delay in TB820/TB820V2(1) 4.0 µs Opto-to-electrical delay in TB820/TB820V2(1) 6.5 µs Opto-to-opto delay in TB840/TB840A (1) 2.0 µs Opto-to-electrical delay in TB840/TB840A (1) 5.5 µs Delay in optical fiber (1)(2) (0.01 x length) µs (1) Notice that the delays in the table is the sum of the communication delay in both directions, i.e. (delay of master frame) + (delay of slave frame). (2) Total fiber length = total local fiber length + field fiber length 148 3BSE A

149 Section 3 Technical Data and Performance Calculation of Maximum Distance of an Optical AC800 LF 15 m TB820 I/O LF 15 m TB820 I/O LF 15 m TB820 I/O LF 15 m TB820 I/O LF 1.5 m TB820 I/O LF 1.5 m FF TB m LF = Local fiber FF = Field fiber E = Electrical Modulebus LF 1.5 m E TB825 TB820 I/O Figure 60. Example of worst case delay configuration Calculation of the ModuleBus delay for the configuration in Figure 60: ModuleBus delay = (total delay in optical fiber) + 5 x (opto-to-opto delay in TB820/TB820V2) + 2 x (delay in TB825) + (opto-to electrical delay in TB820/TB820V2) = (4 x x ) x x x = 42 µs. 3BSE A 149

150 Calculation of Maximum Distance of an Optical ModuleBus Configuration Section 3 Technical Data Calculation of Maximum Fiber length for TB826 The maximum signal delay in a configuration is calculated using Optical Media Converter. This is calculated using the signal path from the controller to the point in the configuration that has the longest delay. The maximum delay in a optical ModuleBus configuration must be 100µs (less than 250µs for S800 I/O HI). The delay values in Table 30 can be used to calculate the maximum delay in an optical ModuleBus configuration. Table 30. Delay Values Optical ModuleBus Components Opto-to-opto delay in TB826 (1) 2.0 µs Opto-to-opto delay in TB820 (1) 4.0 µs Opto-to-electrical delay in TB820 (1) 6.5 µs Opto-to-opto delay in TB840 (1) 2.0 µs Opto-to-electrical delay in TB840 (1) 5.5 µs Delay in optical fiber (1)(2) (0.01 x length) µs (1) Notice that the delays in the table is the sum of the communication delay in both directions, i.e. (delay of master frame) + (delay of slave frame). (2) Total fiber length = total local fiber length + field fiber length 150 3BSE A

151 Section 3 Technical Data and Performance Calculation of Maximum Distance of an Optical Figure 61. Example of worst case delay configuration TB826 For the configuration in Figure 61 the Communication link delay is calculated as: (Total delay in FF) + (Total delay in LF) + 6*(Opto-to-opto delay in TB820/TB820V2) + 2*(Delay in TB826) + (Opto-to-electrical delay in TB820) = 5000* ((7 * 200)+100)* *4 + 2* = * = 99.5 µs 3BSE A 151

152 Power Supply and Cooling Requirements Section 3 Technical Data and Performance Power Supply and Cooling Requirements A quick guide for power consumption to be used in a preliminary phase of a project work or whenever you need estimated figures is provided in Table 31. Table 31. Estimated System Power Consumption S800 I/O Station 24 V d.c. Power Consumption (A) Base cluster, single FCI, with six (6) I/O Modules 0.5 Base cluster, single FCI, with twelve (12) I/O Modules 1.0 Base cluster, redundant FCIs (2), with six (6) I/O Modules 1.0 Base cluster, redundant FCIs (2), with twelve (12) I/O Modules 1.5 Base cluster, redundant FCIs (2), with six (6) pairs of redundant I/O Modules 1.5 Additional I/O cluster with six (6) I/O Modules 0.5 Additional I/O cluster with twelve (12) I/O Modules 1.0 Additional I/O cluster, redundant Optical ModuleBus modem (2), with six (6) pairs of redundant I/O Modules (1) Additional I/O cluster, redundant Optical ModuleBus modem (2), with twelve (12) I/O Modules Additional I/O cluster, redundant Optical ModuleBus modem (2), with six (6) I/O Modules (1) One pair of redundant I/O Modules counts as two I/O Modules. The estimates are based on fully loaded I/O stations with a mixed configuration of DI/DO and AI/AO. Only power distributed via the ModuleBus are included. External 24 V connected directly to the I/O modules for external loads and transmitters are not included. When using AO820 and/or DO820/DO821, these load figures may be exceeded and a load calculation can be useful to do, see Table BSE A

153 Section 3 Technical Data and Performance Power Supply and Cooling Requirements Device Power and Cooling Table 32 shows the typical power and cooling values that can be used when designing the S800 I/O. (Calculation of 24V d.c. Power Consumption.) 5 Volts ModuleBus Table 32. I/O Station Power and Cooling (Typical) Values 24 Volts ModuleBus 24 Volts External Power Dissipation (Watts) Cooling Load (1) (BTU/H Typical) Maximum Ambient Temperature AI ma - 30 ma /40 C (131/104 F) (2) AI ma 40 ma /40 C (131/104 F) (2) AI ma 50 ma 22 ma + sensor current /40 C (131/104 F) (2) AI ma 70 ma /40 C (131/104 F) (2) AI ma 110 ma /40 C (131/104 F) (2) AI830/ AI830A AI835/ AI835A 70 ma 50 ma /40 C (131/104 F) (2) 75 ma 50 ma /40 C (131/104 F) (2) AI ma 50 ma /40 C (131/104 F) (2) AI ma 50 ma 22 ma + sensor current AI880/ AI880A 45 ma 50 ma 4 ma + sensor current AI ma ma including sensor current /40 C (131/104 F) (2) /40 C (131/104 F) (2) /40 C (131/104 F) (2) 3BSE A 153

154 Power Supply and Cooling Requirements Section 3 Technical Data and Performance Device AI ma /40 C (131/104 F) (2) AI ma ma including sensor current AO ma ma including load current AO ma ma including load current AO810V2 (3) 70 ma ma including load current AO ma ma including load current /40 C (131/104 F) (2) /40 C (131/104 F) (2) /40 C (131/104 F) (2) /40 C (131/104 F) (2) /40 C (131/104 F) (2) AO ma 260 ma /40 C (131/104 F) (2) AO845/ AO845A Table 32. I/O Station Power and Cooling (Typical) Values (Continued) 5 Volts ModuleBus 24 Volts ModuleBus 24 Volts External 125 ma ma including load current Power Dissipation (Watts) Cooling Load (1) (BTU/H Typical) Maximum Ambient Temperature /40 C (131/104 F) (2) 154 3BSE A

155 Section 3 Technical Data and Performance Power Supply and Cooling Requirements Device AO ma ma including load current AO ma ma including load current /40 C (131/104 F) (2) /40 C (131/104 F) (2) CI ma 5.4 W (3) 19 55/40 C (131/104 F) (10) CI ma C/(131 F) CI820/ CI820V1 CI840/ CI840A Table 32. I/O Station Power and Cooling (Typical) Values (Continued) 5 Volts ModuleBus 24 Volts ModuleBus 24 Volts External ma (4) Power Dissipation (Watts) Cooling Load (1) (BTU/H Typical) Maximum Ambient Temperature C/(131 F) ma (4) /40 C (131/104 F) (10) DI ma /40 C (131/104 F) (2) DI ma /40 C (131/104 F) (2) DI ma /40 C (131/104 F) (2) DI ma /40 C (131/104 F) (2) DI ma /40 C (131/104 F) (2) DI ma /40 C (131/104 F) (2) DI818 70mA - 25mA /40 C (131/104 F) (2) DI ma /40 C (131/104 F) (2) DI ma /40 C (131/104 F) (2) 3BSE A 155

156 Power Supply and Cooling Requirements Section 3 Technical Data and Performance Device DI ma /40 C (131/104 F) (2) DI ma /40 C (131/104 F) (2) DI ma /40 C (131/104 F) (2) DI ma /40 C (131/104 F) (2) DI ma - 15 ma + sensor current DI ma - 15 ma + sensor current /40 C (131/104 F) (2) /40 C (131/104 F) (2) DI ma 91 ma (5) 91 ma (5) /40 C (131/104 F) (2) DI ma - 70 ma including sensor current /40 C (131/104 F) (2) DO ma - (6) /40 C (131/104 F) (2) DO ma 80 ma /40 C (131/104 F) (2) DO ma - DO ma - Table 32. I/O Station Power and Cooling (Typical) Values (Continued) 5 Volts ModuleBus 24 Volts ModuleBus 24 Volts External (6) (6) Power Dissipation (Watts) Cooling Load (1) (BTU/H Typical) Maximum Ambient Temperature /40 C (131/104 F) (2) /40 C (131/104 F) (2) DO ma - (7) /40 C (131/104 F) (2) DO ma - 40 ma /40 C (131/104 F) (2) DO ma 140 ma /40 C (131/104 F) (2) DO ma 140 ma /40 C (131/104 F) (2) DO ma 80 ma /40 C (131/104 F) (2) 156 3BSE A

157 Section 3 Technical Data and Performance Power Supply and Cooling Requirements Device DO ma ma + channel load (6) DO ma 55 ma 10 ma + channel load (6)(8) /40 C (131/104 F) (2) 5.6 (9) 19 55/40 C (131/104 F) (2) DO ma ma /40 C (131/104 F) (2) DP ma - (6) /40 C (131/104 F) (2) DP ma - 70 ma (6) /40 C (131/104 F) (2) TB ma 20 ma C/(131 F) TB ma 20 ma C/(131 F) TB820/ TB820V2 Table 32. I/O Station Power and Cooling (Typical) Values (Continued) 5 Volts ModuleBus 24 Volts ModuleBus 24 Volts External Power Dissipation (Watts) Cooling Load (1) (BTU/H Typical) Maximum Ambient Temperature ma C/(131 F) TB ma C/(131 F) TB ma C/(131 F) TB ma (4) /40 C (131/104 F) (10) TB ma 20 ma C/(131 F) SD /8 (11) 34/27 55 C/(131 F) (12) SD /13 (11) 47/44 55 C/(131 F) (12) SD /22 (11) 81/75 55 C/(131 F) (12) SD834 40/31 (11) 136/ C/(131 F) (12) 3BSE A 157

158 Power Supply and Cooling Requirements Section 3 Technical Data and Performance Device Table 32. I/O Station Power and Cooling (Typical) Values (Continued) 5 Volts ModuleBus 24 Volts ModuleBus 24 Volts External Power Dissipation (Watts) Cooling Load (1) (BTU/H Typical) Maximum Ambient Temperature SS C/(131 F) (12) SS C/(131 F) (12) (1) Cooling load is the heat (BTU/H) produced by the equipment that may be required to meet room or enclosure cooling specifications. (2) 40 C (104 F) applies to Compact MTUs with I/O modules or S800L mounted on a vertical DIN-rail. (3) With maximum load at ModuleBus 24 V and 5V (4) In redundant configuration twice (5) 24 V from ModuleBus (91 ma) or 24 V external (91 ma) or 48 V external (22 ma). (6) 500 ma per channel with maximum load per channel. (7) 2 A per channel with maximum load per channel. (8) Short circuit current <15 A during 20 ms. (9) With maximum channel load (10) 40 C (104 F) mounter on a vertical DIN-rail. (11) a.c. 120/230V. (12) Horizontal mounting only BSE A

159 Section 3 Technical Data and Performance Power Supply and Cooling Requirements Calculation of 24V d.c. Power Consumption Total 24 V d.c. current consumption = V load ModuleBus + V load ModuleBus*0.3 + V external load. The calculated 5 V ModuleBus load should not exceed 1.5 A. If many of the modules has a power consumption >125 ma at 5 V, the maximum load could be exceeded. See Table 32 for data. The calculated 24 V ModuleBus load should not exceed 1.4 A. If many of the modules has a power consumption >125 ma at 24 V, the maximum load could be exceeded. To ensure bumpless performance of the I/O system including DO880, the power supply for the I/O field power should be able to support at least short circuit on one DO880 channel in addition to the total nominal load. For Short circuit current for DO880, see Technical Data in S800 I/O Modules and Termination Units. The following rules must be considered if ABB power supply units are being used together with DO When using SS823, the base load must not exceed 16 A. - With a redundant power supply configuration, consisting of two SD823 + one SS823 in parallel with two SD823 + one SS823, the base load must not exceed 16 A. 3BSE A 159

160 Power Supply and Cooling Requirements Section 3 Technical Data and Performance I/O Module MTU Combination and Key Setting Each MTU is used with certain types of I/O Modules. Refer to Table 33 and Table 34 for a cross-reference between MTU and I/O Modules. Each MTU has two mechanical keys that have to be set for the type of I/O module that will be installed on it. Table 33. MTU Usage and Key Settings Module Type TU810 TU812 TU814 Compact TU818 Compact TU819 Compact TU811 TU813 Compact TU830 TU833 Extended TU831 Extended TU834 Extended TU835 Extended TU836 TU837 TU838 Extended TU839 Extended TU842 TU843 TU852 Redundant TU844 TU845 TU854 Redundant TU850 Extended TU851 Extended Mech. Key Setting Key 1 Key 2 AI810 X X X - - X - - X - X X - A E AI815 X X X - - X - - X - X C C AI820 X X X B B AI X - X D A AI830/ AI830A X AI835/ X AI835A X X X A F X - - X B A AI X - - X X B A AI845 X X X - - X - - X - X - - X - - C C AI X X - - F F AI880A X X - - F D AO810/ AO810V2 X X X A E AO815 X X X D B 160 3BSE A

161 Section 3 Technical Data and Performance Power Supply and Cooling Requirements Table 33. MTU Usage and Key Settings (Continued) Module Type TU810 TU812 TU814 Compact TU818 Compact TU819 Compact TU811 TU813 Compact TU830 TU833 Extended TU831 Extended TU834 Extended TU835 Extended TU836 TU837 TU838 Extended TU839 Extended TU842 TU843 TU852 Redundant TU844 TU845 TU854 Redundant TU850 Extended TU851 Extended Mech. Key Setting Key 1 Key 2 AO820 X X X B C AO845 X X X C C AO845A X X X X D B DI810 X X X - - X X X - A A DI811 X X X - - X X X - B D DI814 X X X X B E DI X X - X E A DI X - X X X A B DI X - X X X A C DI X - X X X A B DI X E B DI830 X X X - - X X X - A A DI831 X X X - - X X X - B D DI840 X X X - - X X - X C D DI880 X X (1) X - - X (2) X (2) F F DI885 X X X - - X B F DO810 X X X A A DO814 X X X X B E 3BSE A 161

162 Power Supply and Cooling Requirements Section 3 Technical Data and Performance Table 33. MTU Usage and Key Settings (Continued) Module Type TU810 TU812 TU814 Compact TU818 Compact TU819 Compact TU811 TU813 Compact TU830 TU833 Extended TU831 Extended TU834 Extended TU835 Extended TU836 TU837 TU838 Extended TU839 Extended TU842 TU843 TU852 Redundant TU844 TU845 TU854 Redundant TU850 Extended TU851 Extended Mech. Key Setting Key 1 Key 2 DO815 X X (3) X A A DO X X - X E A DO X - X - - X X A D DO X - X - - X X C A DO X E D DO840 X X X X C E DO880 X X X X F E DP820 X X X C B DP840 X X X - - X X X - - C F (1) If single Compact MTUs (TU810, TU812 or TU814) are used, refer to the Technical Description 3BSE (2) If the outgoing sensor supplies are not used to feed the sensor in the field, refer to the Technical Description 3BSE (3) TU812 is not recommended due to the maximum rated current BSE A

163 Section 3 Technical Data and Performance Power Supply and Cooling Requirements Table 34. MTU Usage and Key Settings for Intrinsic Safety Interfacing Units Module Type TU890/TU891 Compact Mech. Key Setting (1) Key 1 Key 2 AI890 X A C AI893 X B A AI895 X A E AO890 X A D AO895 X A F DI890 X A A DO890 X A B (1) Note that the shape and style of the key on the TU890/TU891 MTUS is different from the standard MTU s. Module Type Table 35. MTU Usage and Key Settings for CI840 and TB840 TU840/ TU841 TU846/ TU847 Mech. Key Settings Key1 Key 2 CI840 X A A TB840 X A B 3BSE A 163

164 Supported I/O Modules and Drives via Advant Fieldbus 100 Section 3 Technical Data and Supported I/O Modules and Drives via Advant Fieldbus 100 The following I/O modules are supported by the Advant Fieldbus 100 Field Communication Interface module CI810 and CI820: AI801, AI810, AI820, AI830, AI830A, AI835, AI890, AI895 AO801, AO810, AO810V2, AO820, AO890, AO895 DI801, DI810, DI811, DI814, DI820, DI821, DI830, DI831, DI885, DI890 DO801, DO810, DO814, DO815, DI820, DO821, DO890 DP820 ABB Standard Drives ABB Engineered Drives Supported I/O Modules and Drives via PROFIBUS and CI801 The following I/O modules are supported by the PROFIBUS Field Communication Interface module CI801: AI801, AI810, AI815, AI820, AI825, AI830, AI830A, AI835, AI843, AI845, AI890, AI893, AI895 AO801, AO810, AO815, AO810V2, AO820, AO845, AO845A, AO890, AO895 DI801, DI802, DI803, DI810, DI811, DI814, DI818, DI820, DI821, DI828, DI840 (SOE handling not supported), DI890 DO801, DO802, DO810, DO814, DO815, DO818, DO820, DO821, DO828, DO840, DO890 DP820, DP840 ABB Standard Drives (Equipped with opto transmitter/receiver for up to 10 Mbit/s on the ModuleBus.) ACS600/ACS800 with standard application 164 3BSE A

165 Section 3 Technical Data and Performance Supported I/O Modules and Drives via PROFIBUS and ACS600/ACS800/DCS600 with crane application ACS600/ACS800 with pump and fan application (PFC) ACS400/DCS500/DCS400 with standard drive Supported I/O Modules and Drives via PROFIBUS and CI840 The following I/O modules are supported by the PROFIBUS Field Communication Interface module CI840. Check the controller documentation for information about I/O module support implemented in the controller: AI801, AI810, AI815, AI820, AI825, AI830, AI830A, AI835, AI843, AI845, AI890, AI893, AI895 AO801, AO810, AO815, AO810V2, AO820, AO845, AO845A, AO890, AO895 DI801, DI802, DI803, DI810, DI811, DI814, DI818, DI820, DI821, DI828, DI825 1, DI830 1, DI831 1, DI840 (SOE handling not supported), DI885 1, DI890 DO801, DO802, DO810, DO814, DO815, DO818, DO820, DO821, DO828, DO840, DO890 DP820, DP Not supported by AC 800M 3BSE A 165

166 Intrinsic Safety Parameters Section 3 Technical Data and Performance Intrinsic Safety Parameters The following Intrinsic Safety parameters apply for AI890 Table 36, AI893 Table 37, AI895 Table 38, AO890 and AO895 Table 39, DI890 Table 40 and DO890 Table 41. Table 36. AI890 Analog Input Module Intrinsic Safety Parameters Terminals Powered transmitter terminals Passive input terminals (1) Safety Description Maximum External Parameters Groups CENELEC USA C 0 (uf) L 0 (mh) L/R (uh/o) U 0 = 27 V IIC AB I 0 = 92 ma IIB CE P 0 = 621 mw IIA DFG U 0 = 30 V IIC AB I 0 = 1.25 ma IIB CE P 0 = 937 mw IIA DFG (1) Non energy-storing apparatus connection Table 37. AI893 Analog Input Module Intrinsic Safety Parameters Terminals Input terminals Safety description Maximum external parameters Groups CENELEC USA C 0 (uf) L 0 (mh) L/R (uh/o) U 0 = 12 V IIC AB I 0 = 20 ma IIB CE P 0 = 60 mw IIA DFG BSE A

167 Section 3 Technical Data and Performance Intrinsic Safety Parameters Table 38. AI895 Analog Input Module Intrinsic Safety Parameters Terminals 1-10, , , , 8-17 Safety Description Maximum External Parameters Groups CENELEC USA C 0 (uf) L 0 (mh) L/R (uh/o) U 0 = 27 V IIC AB I 0 = 93 ma IIB CE P 0 = 630 mw IIA DFG Table 39. AO890/AO895 Analog Output Module Intrinsic Safety Parameters Terminals Powered output terminals Safety description Maximum external parameters Groups CENELEC USA C 0 (uf) L 0 (mh) L/R (uh/o) U 0 = 27 V IIC AB I 0 = 93 ma IIB CE P 0 = 620 mw IIA DFG Table 40. DI890 Digital Input Module Intrinsic Safety Parameters Terminals Input terminals Safety description Maximum external parameters Groups CENELEC USA C 0 (uf) L 0 (mh) L/R (uh/o) U 0 = 11V IIC AB I 0 = 21 ma IIB CE P 0 = mw IIA DFG BSE A 167

168 Intrinsic Safety Parameters Section 3 Technical Data and Performance Table 41. DO890 Digital Input Module Intrinsic Safety Parameters Terminals Powered output terminals Safety description Maximum external parameters Groups CENELEC USA C 0 (uf) L 0 (mh) L/R (uh/o) U 0 = 26 V IIC AB I 0 = 93 ma IIB CE P 0 = 605 mw IIA DFG BSE A

169 Section 3 Technical Data and Performance Certifications Certifications The S800 I/O system is continuously enhanced with additional certificates. The table below describes the situation at the printing of this Product Guide. Table 42. Current Certifications for S800 Modules Module Type CE culus El. safety Haz loc C1 Zone 2 (1) FM El. safety Haz loc C1, Div 2 CSA El. safety Haz loc C1, Div 2 ATEX Zone 2 Category 3 (1) G (2) ATEX Zone 2 Category 3 G (3) SIL1-3 culus El. safety Analog Input Modules AI801 X X X X AI810 X X X X AI820 X X X X AI815 X X AI825 X X AI830 X X X X AI830A X X X X AI835 X X X X AI835A X X X X AI843 X X AI845 X X AI880/ AI880A X X X X AI890 X X (4) X (4) X AI893 X X AI895 X X (4) X (4) X 3BSE A 169

170 Certifications Section 3 Technical Data and Performance Table 42. Current Certifications for S800 Modules (Continued) Module Type CE culus El. safety Haz loc C1 Zone 2 (1) FM El. safety Haz loc C1, Div 2 CSA El. safety Haz loc C1, Div 2 ATEX Zone 2 Category 3 (1) G (2) ATEX Zone 2 Category 3 G (3) SIL1-3 culus El. safety Analog Output Modules AO801 X X X X AO810 X X X X AO810V2 X X X X AO815 X X AO820 X X X X AO845 X X AO845A X X AO890 X X (4) X (4) X AO895 X X (4) X (4) X Field Communication Interface CI801 X X CI810B X X X X CI820V1 X X X X CI830 X X X X CI840 X X CI840A X X TB815 X X X X 170 3BSE A

171 Section 3 Technical Data and Performance Certifications Table 42. Current Certifications for S800 Modules (Continued) Module Type CE culus El. safety Haz loc C1 Zone 2 (1) FM El. safety Haz loc C1, Div 2 CSA El. safety Haz loc C1, Div 2 ATEX Zone 2 Category 3 (1) G (2) ATEX Zone 2 Category 3 G (3) SIL1-3 culus El. safety Advant Fieldbus 100 TC501V150 TC506 TC513V1 TC514V2 TC515V2 X X X X X Digital Input Modules DI801 X X X X DI802 X X X X DI803 X X X X DI810 X X X X DI811 X X X X DI814 X X X X DI818 X DI820 X X X X DI821 X X X X DI825 X X DI828 X DI831 X 3BSE A 171

172 Certifications Section 3 Technical Data and Performance Table 42. Current Certifications for S800 Modules (Continued) Module Type CE culus El. safety Haz loc C1 Zone 2 (1) FM El. safety Haz loc C1, Div 2 CSA El. safety Haz loc C1, Div 2 ATEX Zone 2 Category 3 (1) G (2) ATEX Zone 2 Category 3 G (3) SIL1-3 culus El. safety DI830 X X X X DI831 X X X X DI840 X X DI880 X X X X DI885 X X X X DI890 X X (4) X (4) X Digital Output Modules DO801 X X X X DO802 X X X X DO810 X X X X DO814 X X X X DO815 X X X X DO818 X DO820 X X X X DO821 X X X X DO828 X DO840 X X DO880 X X X X DO890 X X (4) X (4) X 172 3BSE A

173 Section 3 Technical Data and Performance Certifications Table 42. Current Certifications for S800 Modules (Continued) Module Type CE culus El. safety Haz loc C1 Zone 2 (1) FM El. safety Haz loc C1, Div 2 CSA El. safety Haz loc C1, Div 2 ATEX Zone 2 Category 3 (1) G (2) ATEX Zone 2 Category 3 G (3) SIL1-3 culus El. safety SD821 (5) X X SD822 (5) X X SD823 (5) X X X SS822 (5) X X SD832 X X SD833 X X SD834 X X X SS823 X X X X SS832 X X Pulse Counting Modules DP820 X X X X DP840 X X Module Termination Units TU801 X TU807 X X TU810V1 X X X X TU811V1 X X X X TU812V1 X X X X 3BSE A 173

174 Certifications Section 3 Technical Data and Performance Table 42. Current Certifications for S800 Modules (Continued) Module Type CE culus El. safety Haz loc C1 Zone 2 (1) FM El. safety Haz loc C1, Div 2 CSA El. safety Haz loc C1, Div 2 ATEX Zone 2 Category 3 (1) G (2) ATEX Zone 2 Category 3 G (3) SIL1-3 culus El. safety TU813 X X TU814V1 X X X X TU818 X TU819 X TU830V1 X X X X TU831V1 X X X X TU833 X X TU834 X X TU835V1 X X X X TU836V1 X X TU837V1 X X X X TU838 X X X X TU839 X X TU840 X X X TU841 X X X TU842 X X X TU843 X X X TU844 X X X TU845 X X X TU846 X X 174 3BSE A

175 Section 3 Technical Data and Performance Certifications Table 42. Current Certifications for S800 Modules (Continued) Module Type CE culus El. safety Haz loc C1 Zone 2 (1) FM El. safety Haz loc C1, Div 2 CSA El. safety Haz loc C1, Div 2 ATEX Zone 2 Category 3 (1) G (2) ATEX Zone 2 Category 3 G (3) SIL1-3 culus El. safety TU847 X X TU848 X X TU849 X X TU850 X X TU851 TU852 TU854 X X X TU890 X X (4) X (4) X TU891 X TY801 X X X TY804 X ModuleBus Communication Parts TB805 X X X X TB806 X X X X TK801V003 TK801V006 TK801V001 2 X X X TB807 X X X X TB810 X X X X TB811 X X X X 3BSE A 175

176 Certifications Section 3 Technical Data and Performance Table 42. Current Certifications for S800 Modules (Continued) Module Type CE culus El. safety Haz loc C1 Zone 2 (1) FM El. safety Haz loc C1, Div 2 CSA El. safety Haz loc C1, Div 2 ATEX Zone 2 Category 3 (1) G (2) ATEX Zone 2 Category 3 G (3) SIL1-3 culus El. safety TB820V2 X X X X TB825 X X TB826 X X TB840/ TB840A X X X TB842 X X TB845 X X TB846 X X (1) Marking for mounting and interface: Class 1 Zone 2 AEx nc (or na) IIC T4 and CL 1 DIV 2 GP A B C D T4 (2) Marking for mounting: Ex II 3G EEx na [ia] IIC T4 Marking for interface: Ex II (1)G [EEx ia] IIC (3) Marking for mounting and interface: Ex II 3G Ex na IIC T5 Gc (4) Provides Intrinsically safe circuit for Cl. I, Div 1; Cl. II, Div. 1; Cl. III, Div 1 or Cl. I, Zone 0 group IIc (5) culus; UL508, UL1950, CSA 22.2 No BSE A

177 Section 4 Ordering General This Product Guide aims to help ABB sales representatives when ordering the S800 I/O product and licenses. This section describes the price lists needed when ordering and provides ordering examples. However, it is outside the scope of this Product Guide to give a complete description of all ordering procedures and tools, as well as licensing conditions for other Industrial IT products. Each ABB sales representative is assumed to know how to use price lists, CAST and other tools to order. Product and Price List Structure S800 I/O is ordered as separate parts. From the current price list, you order the modules you need for your system. For further details, refer the valid S800 I/O Price List. 3BSE A 177

178 Product and Price List Structure Section 4 Ordering 178 3BSE A

179 A Advant Fieldbus AI AI810 50, 58 AI AI AI AI830/ AI830A 51 AI830A 51 AI835/ AI835A 51 AI AI AI880/ AI880A 52 AI AI AI AO AO AO810/ AO810V2 53 AO810V2 53, 58 AO AO AO845/ AO845A 53 AO845A 53 AO AO B Built in 2/3 wire termination 109 C Calculation of 24V d.c. power consumption 153, 159 CI CI CI820/CI820V1 36 CI840/ CI840A 36 Compact MTUs 66 Cooling load 153 DI DI DI DI810 44, 58 DI DI DI DI DI DI DI DI DI DI DI DI DI DO DO DO810 47, 58 DO DO DO DO DO DO DO DO DO D INDEX 3BSE A 179

180 Index DP DP Extension cables 88, 89 FCI 11 HART 11 I/O station 12 E F H M Maximum ambient temperature 153 Module Termination Units (MTU) 65 I P Power and Cooling 153 Power consumption 152 Power Dissipation 153 PROFIBUS-DP 12, 19, 28 SD822Z 93 SD SD SD SD SS822Z 94 SS SS TB TB TB S T TB TB TB815 36, 41 TB820/ TB820V2 41 TB TB TB840/ TB840A 41 TB TB TB TK801V TK801V TK801V TK811V TK811V TK811V TK812V TK812V TK812V TU TU TU TU TU TU812/ TU812V1 37 TU TU814/ TU814V1 37 TU830/ TU830V1 38 TU831/ TU831V1 38 TU TU TU835/ TU835V1 38 TU836/ TU836V1 38 TU837/ TU837V1 38 TU TU TU TU TU TU BSE A

181 Index TU TU TU TU TU TU TU TU TU TY TY TY BSE A 181

182 Index 3BSE A 182

183

184 Contact us ABB AB Control Technologies Västerås, Sweden Phone: +46 (0) ABB Automation GmbH Control Technologies Mannheim, Germany Phone: ABB Automation LLC Control Technologies Abu Dhabi, United Arab Emirates Phone: +971 (0) [email protected] ABB China Ltd Control Technologies Beijing, China Phone: +86 (0) BSE A ABB S.P.A. Control Technologies Sesto San Giovanni (MI), Italy Phone: [email protected] Copyright by ABB. All rights reserved. ABB Inc. Control Technologies Wickliffe, Ohio, USA Phone: [email protected] ABB Pte Ltd Control Technologies Singapore Phone: [email protected] Power and productivity for a better world TM